Drive belt tensioner systems and methods

ABSTRACT

Embodiments of the present disclosure include a drive belt tensioner configured to adjust tension in a drive belt of a blower assembly for a heating, ventilation, and/or air conditioning (HVAC) system. The drive belt tensioner includes a mounting bracket configured to couple directly to a blower housing that is configured to house a blower of the blower assembly. The drive belt tensioner further includes an idler pulley configured to contact the drive belt. A position of the idler pulley is adjustable relative to the mounting bracket to enable adjustment of the tension in the drive belt.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 62/838,860, entitled “DRIVE BELTTENSIONER SYSTEMS AND METHODS”, filed Apr. 25, 2019, which is hereinincorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure relates generally to heating, ventilation, and/orair conditioning (HVAC) systems and, more particularly, to systems andmethods for adjusting tension in a drive belt of HVAC systems.

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present techniques,which are described and/or claimed below. This discussion is believed tobe helpful in providing the reader with background information tofacilitate a better understanding of the various aspects of the presentdisclosure. Accordingly, it should be understood that these statementsare to be read in this light, and not as an admission of any kind.

A wide range of applications exist for HVAC systems. For example,residential, light commercial, commercial, and industrial systems areused to control temperatures and air quality in residences andbuildings. Such systems may be dedicated to either heating or cooling,although systems are common that perform both of these functions. Verygenerally, these systems operate by implementing a thermal cycle inwhich fluids are heated and cooled to provide a desired temperature in acontrolled space, such as the inside of a residence or a building.Generally, HVAC units may include a blower that is configured to driveair flow through the HVAC unit. The blower is typically powered by amotor. Particularly, the motor may transfer power to the blower viadrive belt. At times, a tension of the drive belt may be adjusted.

SUMMARY

In one embodiment of the present disclosure, a belt tensioner for ablower assembly includes a mounting bracket configured to coupledirectly to the blower assembly and an idler arm configured to couple tothe mounting bracket at a connection point and in an angular positionrelative to a base of the blower assembly. The angular position isadjustable about the connection point. The belt tensioner furtherincludes an idler pulley coupled to the idler arm. The idler pulley isconfigured to engage with a drive belt of the blower assembly.

In another embodiment of the present disclosure, a heating, ventilation,and/or air conditioning (HVAC) system includes a blower assembly havinga blower, a blower housing configured to house the blower, a motorconfigured to provide rotational power, and a drive belt configured totransfer the rotational power from the motor to the blower. The HVACsystem further includes a belt tensioner having an L-shaped support witha first arm coupled to an idler pulley and a second arm. The first armand the second arm are coupled to one another at a bend. The L-shapedsupport is rotatably coupled to the blower housing via a mountingbracket. The idler pulley is configured to contact the drive belt tofacilitate tensioning of the drive belt.

In a further embodiment of the present disclosure, a blower assembly fora heating, ventilation, and/or air conditioning (HVAC) system includes ablower fan, a blower housing containing the blower fan, and a drive beltcoupled to the blower fan and configured to drive rotation of the blowerfan. The HVAC system further includes a belt tensioner having anL-shaped bracket that is coupled to the blower housing via a mountingbracket. The L-shaped bracket is rotatably coupled to the mountingbracket at a bend of the L-shaped bracket.

In a further embodiment of the present disclosure, a belt tensioner fora blower assembly includes a guide rail configured to couple directly tothe blower assembly and an idler mounting plate configured to slidealong the guide rail, such that a position of the idler mounting plateis linearly adjustable relative to the guide rail. The belt tensionerfurther includes an idler pulley coupled to the idler mounting plate.The idler pulley is configured to engage with a drive belt of the blowerassembly.

In a further embodiment of the present disclosure, a heating,ventilation, and/or air conditioning (HVAC) system includes a blowerassembly having a blower, a blower housing configured to house theblower, a motor configured to provide rotational power, and a drive beltconfigured to transfer the rotational power from the motor to theblower. The HVAC system further includes a belt tensioner having a guiderail configured to mount directly to the blower housing, an idlermounting plate configured to move linearly along the guide rail, anidler pulley configured to mount to the idler mounting plate, and a boltconfigured to couple to the idler mounting plate and to a lock plate,such that rotation of the bolt linearly adjusts a position of the idlerpulley relative to the drive belt.

In a further embodiment of the present disclosure a heating,ventilation, and/or air conditioning (HVAC) system includes a guide railconfigured to couple directly to a blower housing of the HVAC system andan idler mounting plate configured to support an idler pulley and havinga first hole disposed through a first flange of the idler mountingplate. The idler mounting plate is configured to slide along the guiderail to adjust a position of the idler pulley relative to a blower drivebelt of the HVAC system. The HVAC system further includes a lock platehaving a second hole disposed through a second flange of the lock plate.The lock plate is configured to couple directly to the blower housing.The HVAC system further includes a bolt configured to extend through thefirst hole of the first flange of the idler mounting plate and throughthe second hole of the second flange of the lock plate. Rotation of thebolt is configured to adjust a position of the idler mounting platerelative to the guide rail to adjust the position of the idler pulley.

In a further embodiment of the present disclosure, a belt tensioner fora blower assembly includes a mounting bracket configured to coupledirectly to the blower assembly, an idler arm configured to rotatablycouple to the mounting bracket and having a first side and a secondside, and an idler pulley rotatably coupled to the idler arm. The idlerpulley is configured to engage with a drive belt of the blower assembly.The belt tensioner further includes a tension spring coupled to themounting bracket and to the first side of the idler arm, and acompression spring coupled to the mounting bracket and to the secondside of the idler arm.

In a further embodiment of the present disclosure a heating,ventilation, and/or air conditioning system includes a blower housing, amounting bracket configured to mount to the blower housing, and an idlerarm configured to rotatably couple to the mounting bracket. The HVACsystem further includes a first linear spring configured to couple to afirst side of the idler arm and to the mounting bracket, a second linearspring configured to couple to a second side of the idler arm and to themounting bracket, and an idler pulley configured to couple to an end ofthe idler arm and to engage with a drive belt of the HVAC system.

In a further embodiment of the present disclosure a heating,ventilation, and/or air conditioning (HVAC) system includes a blowerassembly having a blower, a blower housing configured to house theblower, a motor configured to provide rotational power, and a drive beltconfigured to transfer the rotational power from the motor to theblower. The HVAC system further includes a belt tensioner having amounting bracket configured to mount directly to the blower housing, anidler arm configured to rotatably mount to the mounting bracket at apivot point, an idler pulley configured to rotationally mount to an endof the idler arm distal to the pivot point, and a set of linear springscoupled between the idler arm and the mounting bracket. Each linearspring of the set of linear springs is configured to be linearlyactuated in response to engagement between the idler pulley and thedrive belt.

Other features and advantages of the present application will beapparent from the following, more detailed description of theembodiments, taken in conjunction with the accompanying drawings, whichillustrate, by way of example, the principles of the application.

DRAWINGS

FIG. 1 is a perspective view of an embodiment of a heating, ventilation,and/or air conditioning (HVAC) system for building environmentalmanagement that may employ one or more HVAC units, in accordance withaspects of the present disclosure;

FIG. 2 is a perspective view of an embodiment of a packaged HVAC unit,in accordance with aspects of the present disclosure;

FIG. 3 is a perspective view of an embodiment of a residential splitheating and cooling system, in accordance with aspects of the presentdisclosure;

FIG. 4 is a schematic view of an embodiment of a vapor compressionsystem that may be used in an HVAC system, in accordance with aspects ofthe present disclosure;

FIG. 5 is a perspective view of an embodiment of a blower assemblyhaving a belt tensioner, in accordance with aspects of the presentdisclosure;

FIG. 6 is a front view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 7 is a side view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 8 is an exploded perspective view of an embodiment of a belttensioner, in accordance with aspects of the present disclosure;

FIG. 9 is a perspective view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 10 is a side view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 11 is a side view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 12 is a perspective view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 13 is an exploded perspective view of an embodiment of a belttensioner, in accordance with aspects of the present disclosure;

FIG. 14 is a front view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 15 is a perspective view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 16 is a perspective view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 17 is an exploded perspective view of an embodiment of a belttensioner, in accordance with aspects of the present disclosure;

FIG. 18 is a side view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 19 is a side view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 20 is a front view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 21 is a perspective view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure;

FIG. 22 is an exploded perspective view of an embodiment of a belttensioner, in accordance with aspects of the present disclosure;

FIG. 23 is a front view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure; and

FIG. 24 is a front view of an embodiment of a belt tensioner, inaccordance with aspects of the present disclosure.

DETAILED DESCRIPTION

Certain heating, ventilation, and/or air conditioning (HVAC) systems mayinclude a blower, or fan, configured to move air through the HVACsystem. For example, a blower may be used to force air across a heatexchanger, such as an evaporator or a condenser. The blower may bepowered by a motor, which may be configured to deliver power to theblower via a drive belt. That is, the drive belt may transfer rotationalpower from the motor to the blower to cause the blower to rotate andforce an air flow through the HVAC system. The drive belt should be at aproper tension to efficiently transfer power from the motor to theblower. However, over time, the drive belt may become loose, such as dueto stretching of the drive belt. In such instances, slippage of the beltrelative to the motor and/or the blower may occur, which may causeinefficiencies in the HVAC system. Accordingly, it is desirable tooccasionally tighten or increase a tension of the drive belt. Existingsystems for tightening a drive belt of a blower assembly include asystem for mounting the motor on a sliding platform. In such instances,when the drive belt begins to lose tension, the motor may be moved viathe sliding platform to increase a distance between the blower and themotor, thereby tightening, or increasing a tension, of the drive belt.However, such adjustment assemblies may be difficult to access and tomanipulate or maintain. Moreover, such adjustment assemblies may requiremany moving parts, which may cause unnecessary wear on some components.

Accordingly, the present disclosure is directed to an improved belttensioner for a blower of an HVAC system. The belt tensioner may bemounted directly to a blower housing of the blower via a mountingbracket. An idler arm is rotatably coupled to the mounting bracket via abolt or other coupling member, and the idler arm includes an idlerpulley mounting portion coupled to an idler pulley. A drive belt of theblower assembly may extend about the idler pulley, and a tension in thedrive belt may be based on a force applied to the drive belt by theidler pulley. Moreover, the force of the idler pulley on the drive beltmay be adjusted through rotation of the idler arm. For example, theidler pulley mounting portion of the idler arm may include an L-shapedconfiguration rotatably mounted to the mounting bracket about a bend, orfulcrum, of the L-shaped configuration. As an angular position of theidler arm is adjusted, the force that the idler pulley applies to thedrive belt is correspondingly adjusted. For example, rotation of theidler arm may cause the idler pulley to travel in a direction towardsthe drive belt, thereby increasing the force of the idler pulley on thedrive belt and increasing a tension of the drive belt.

The angular position of the idler arm may be adjusted via an adjustmentassembly. For example, in some embodiments, the belt tensioner mayinclude an adjustment plate extending from the idler pulley mountingportion of the idler arm. Moreover, the adjustment assembly may includea bolt extending through the mounting bracket and through the adjustmentplate. As the bolt is rotated, the bolt may cause the adjustment plateto be rotated, thereby adjusting the angular position of the idler arm,and correspondingly adjusting the tension of the drive belt. Further, insome embodiments, the adjustment assembly may include a bolt disposedthrough an arcuate slot of the L-shaped idler arm. The bolt may beloosened to allow the arcuate slot to move along the bolt, and therebyallowing rotational repositioning of the idler arm about the fulcrum.

In some embodiments, the improved belt tensioner may include a guiderail coupled directly to the blower housing, a lock plate coupleddirectly to the blower housing, and an idler mounting plate configuredto slide within the guide rail and support an idler pulley configured toapply tension to the drive belt. The belt tensioner may further includea bolt or other adjustable component configured to extend between andcouple to the lock plate and the idler mounting plate. Rotation of thebolt causes the idler mounting plate and the idler pulley to linearlytranslate relative to the blower housing and the drive belt to adjust aforce that the idler pulley applies to the drive belt.

In some embodiments, the improved belt tensioner may include a set ofsprings coupled to sides of an idler arm. An idler pulley is coupled toa distal end of the idler arm and is configured to apply tension to thedrive belt. As the drive belt provides a reactive load against the idlerpulley, the set of springs may actuate to automatically adjust tensionin the drive belt. Particularly, the belt tensioner may include acompression spring and a tension spring. The compression spring isconfigured to compress and the tensioner spring is configured toelongate in response to engagement between the idler pulley and thedrive belt. The multi-spring configuration and action may enable anactive distribution of the drive belt load between the springs, therebyincreasing longevity of the springs, the belt tensioner, and the drivebelt.

Accordingly, embodiments of the disclosed belt tensioner are configuredto adjust a tension in the drive belt in an efficient and cost-effectivemanner and without adjustment to a position of the motor of the blowerassembly.

Turning now to the drawings, FIG. 1 illustrates an embodiment of aheating, ventilation, and/or air conditioning (HVAC) system forenvironmental management that may employ one or more HVAC units. As usedherein, an HVAC system includes any number of components configured toenable regulation of parameters related to climate characteristics, suchas temperature, humidity, air flow, pressure, air quality, and so forth.For example, an “HVAC system” as used herein is defined asconventionally understood and as further described herein. Components orparts of an “HVAC system” may include, but are not limited to, all, someof, or individual parts such as a heat exchanger, a heater, an air flowcontrol device, such as a fan, a sensor configured to detect a climatecharacteristic or operating parameter, a filter, a control deviceconfigured to regulate operation of an HVAC system component, acomponent configured to enable regulation of climate characteristics, ora combination thereof. An “HVAC system” is a system configured toprovide such functions as heating, cooling, ventilation,dehumidification, pressurization, refrigeration, filtration, or anycombination thereof. The embodiments described herein may be utilized ina variety of applications to control climate characteristics, such asresidential, commercial, industrial, transportation, or otherapplications where climate control is desired.

In the illustrated embodiment, a building 10 is air conditioned by asystem that includes an HVAC unit 12. The building 10 may be acommercial structure or a residential structure. As shown, the HVAC unit12 is disposed on the roof of the building 10; however, the HVAC unit 12may be located in other equipment rooms or areas adjacent the building10. The HVAC unit 12 may be a single package unit containing otherequipment, such as a blower, integrated air handler, and/or auxiliaryheating unit. In other embodiments, the HVAC unit 12 may be part of asplit HVAC system, such as the system shown in FIG. 3, which includes anoutdoor HVAC unit 58 and an indoor HVAC unit 56. The HVAC unit 12 is anair cooled device that implements a refrigeration cycle to provideconditioned air to the building 10. Specifically, the HVAC unit 12 mayinclude one or more heat exchangers across which an airflow is passed tocondition the airflow before the airflow is supplied to the building. Inthe illustrated embodiment, the HVAC unit 12 is a rooftop unit (RTU)that conditions a supply air stream, such as environmental air and/or areturn airflow from the building 10. After the HVAC unit 12 conditionsthe air, the air is supplied to the building 10 via ductwork 14extending throughout the building 10 from the HVAC unit 12. For example,the ductwork 14 may extend to various individual floors or othersections of the building 10. In certain embodiments, the HVAC unit 12may be a heat pump that provides both heating and cooling to thebuilding with one refrigeration circuit configured to operate indifferent modes. In other embodiments, the HVAC unit 12 may include oneor more refrigeration circuits for cooling an air stream and a furnacefor heating the air stream.

A control device 16, one type of which may be a thermostat, may be usedto designate the temperature of the conditioned air. The control device16 also may be used to control the flow of air through the ductwork 14.For example, the control device 16 may be used to regulate operation ofone or more components of the HVAC unit 12 or other components, such asdampers and fans, within the building 10 that may control flow of airthrough and/or from the ductwork 14. In some embodiments, other devicesmay be included in the system, such as pressure and/or temperaturetransducers or switches that sense the temperatures and pressures of thesupply air, return air, and so forth. Moreover, the control device 16may include computer systems that are integrated with or separate fromother building control or monitoring systems, and even systems that areremote from the building 10.

FIG. 2 is a perspective view of an embodiment of the HVAC unit 12. Inthe illustrated embodiment, the HVAC unit 12 is a single package unitthat may include one or more independent refrigeration circuits andcomponents that are tested, charged, wired, piped, and ready forinstallation. The HVAC unit 12 may provide a variety of heating and/orcooling functions, such as cooling only, heating only, cooling withelectric heat, cooling with dehumidification, cooling with gas heat, orcooling with a heat pump. As described above, the HVAC unit 12 maydirectly cool and/or heat an air stream provided to the building 10 tocondition a space in the building 10.

As shown in the illustrated embodiment of FIG. 2, a cabinet 24 enclosesthe HVAC unit 12 and provides structural support and protection to theinternal components from environmental and other contaminants. In someembodiments, the cabinet 24 may be constructed of galvanized steel andinsulated with aluminum foil faced insulation. Rails 26 may be joined tothe bottom perimeter of the cabinet 24 and provide a foundation for theHVAC unit 12. In certain embodiments, the rails 26 may provide accessfor a forklift and/or overhead rigging to facilitate installation and/orremoval of the HVAC unit 12. In some embodiments, the rails 26 may fitinto “curbs” on the roof to enable the HVAC unit 12 to provide air tothe ductwork 14 from the bottom of the HVAC unit 12 while blockingelements such as rain from leaking into the building 10.

The HVAC unit 12 includes heat exchangers 28 and 30 in fluidcommunication with one or more refrigeration circuits. Tubes within theheat exchangers 28 and 30 may circulate refrigerant (for example,R-410A, steam, or water) through the heat exchangers 28 and 30. Thetubes may be of various types, such as multichannel tubes, conventionalcopper or aluminum tubing, and so forth. Together, the heat exchangers28 and 30 may implement a thermal cycle in which the refrigerantundergoes phase changes and/or temperature changes as it flows throughthe heat exchangers 28 and 30 to produce heated and/or cooled air. Forexample, the heat exchanger 28 may function as a condenser where heat isreleased from the refrigerant to ambient air, and the heat exchanger 30may function as an evaporator where the refrigerant absorbs heat to coolan air stream. In other embodiments, the HVAC unit 12 may operate in aheat pump mode where the roles of the heat exchangers 28 and 30 may bereversed. That is, the heat exchanger 28 may function as an evaporatorand the heat exchanger 30 may function as a condenser. In furtherembodiments, the HVAC unit 12 may include a furnace for heating the airstream that is supplied to the building 10. While the illustratedembodiment of FIG. 2 shows the HVAC unit 12 having two of the heatexchangers 28 and 30, in other embodiments, the HVAC unit 12 may includeone heat exchanger or more than two heat exchangers.

The heat exchanger 30 is located within a compartment 31 that separatesthe heat exchanger 30 from the heat exchanger 28. Fans 32 draw air fromthe environment through the heat exchanger 28. Air may be heated and/orcooled as the airflows through the heat exchanger 28 before beingreleased back to the environment surrounding the rooftop unit 12. Ablower assembly 34, powered by a motor 36, draws air through the heatexchanger 30 to heat or cool the air. The heated or cooled air may bedirected to the building 10 by the ductwork 14, which may be connectedto the HVAC unit 12. Before flowing through the heat exchanger 30, theconditioned airflows through one or more filters 38 that may removeparticulates and contaminants from the air. In certain embodiments, thefilters 38 may be disposed on the air intake side of the heat exchanger30 to prevent contaminants from contacting the heat exchanger 30.

The HVAC unit 12 also may include other equipment for implementing thethermal cycle. Compressors 42 increase the pressure and temperature ofthe refrigerant before the refrigerant enters the heat exchanger 28. Thecompressors 42 may be any suitable type of compressors, such as scrollcompressors, rotary compressors, screw compressors, or reciprocatingcompressors. In some embodiments, the compressors 42 may include a pairof hermetic direct drive compressors arranged in a dual stageconfiguration 44. However, in other embodiments, any number of thecompressors 42 may be provided to achieve various stages of heatingand/or cooling. As may be appreciated, additional equipment and devicesmay be included in the HVAC unit 12, such as a solid-core filter drier,a drain pan, a disconnect switch, an economizer, pressure switches,phase monitors, and humidity sensors, among other things.

The HVAC unit 12 may receive power through a terminal block 46. Forexample, a high voltage power source may be connected to the terminalblock 46 to power the equipment. The operation of the HVAC unit 12 maybe governed or regulated by a control board 48. The control board 48 mayinclude control circuitry connected to a thermostat, sensors, and alarms(one or more being referred to herein separately or collectively as thecontrol device 16). The control circuitry may be configured to controloperation of the equipment, provide alarms, and monitor safety switches.Wiring 49 may connect the control board 48 and the terminal block 46 tothe equipment of the HVAC unit 12.

FIG. 3 illustrates a residential heating and cooling system 50, also inaccordance with present techniques. The residential heating and coolingsystem 50 may provide heated and cooled air to a residential structure,as well as provide outside air for ventilation and provide improvedindoor air quality (IAQ) through devices such as ultraviolet lights andair filters. In the illustrated embodiment, the residential heating andcooling system 50 is a split HVAC system. In general, a residence 52conditioned by a split HVAC system may include refrigerant conduits 54that operatively couple the indoor unit 56 to the outdoor unit 58. Theindoor unit 56 may be positioned in a utility room, an attic, abasement, and so forth. The outdoor unit 58 is typically situatedadjacent to a side of residence 52 and is covered by a shroud to protectthe system components and to prevent leaves and other debris orcontaminants from entering the unit. The refrigerant conduits 54transfer refrigerant between the indoor unit 56 and the outdoor unit 58,typically transferring primarily liquid refrigerant in one direction andprimarily vaporized refrigerant in an opposite direction.

When the system shown in FIG. 3 is operating as an air conditioner, aheat exchanger 60 in the outdoor unit 58 serves as a condenser forre-condensing vaporized refrigerant flowing from the indoor unit 56 tothe outdoor unit 58 via one of the refrigerant conduits 54. In theseapplications, a heat exchanger 62 of the indoor unit functions as anevaporator. Specifically, the heat exchanger 62 receives liquidrefrigerant (which may be expanded by an expansion device, not shown)and evaporates the refrigerant before returning it to the outdoor unit58.

The outdoor unit 58 draws environmental air through the heat exchanger60 using a fan 64 and expels the air above the outdoor unit 58. Whenoperating as an air conditioner, the air is heated by the heat exchanger60 within the outdoor unit 58 and exits the unit at a temperature higherthan it entered. The indoor unit 56 includes a blower or fan 66 thatdirects air through or across the indoor heat exchanger 62, where theair is cooled when the system is operating in air conditioning mode.Thereafter, the air is passed through ductwork 68 that directs the airto the residence 52. The overall system operates to maintain a desiredtemperature as set by a system controller. When the temperature sensedinside the residence 52 is higher than the set point on the thermostat(plus a small amount), the residential heating and cooling system 50 maybecome operative to refrigerate additional air for circulation throughthe residence 52. When the temperature reaches the set point (minus asmall amount), the residential heating and cooling system 50 may stopthe refrigeration cycle temporarily.

The residential heating and cooling system 50 may also operate as a heatpump. When operating as a heat pump, the roles of heat exchangers 60 and62 are reversed. That is, the heat exchanger 60 of the outdoor unit 58will serve as an evaporator to evaporate refrigerant and thereby coolair entering the outdoor unit 58 as the air passes over outdoor the heatexchanger 60. The indoor heat exchanger 62 will receive a stream of airblown over it and will heat the air by condensing the refrigerant.

In some embodiments, the indoor unit 56 may include a furnace system 70.For example, the indoor unit 56 may include the furnace system 70 whenthe residential heating and cooling system 50 is not configured tooperate as a heat pump. The furnace system 70 may include a burnerassembly and heat exchanger, among other components, inside the indoorunit 56. Fuel is provided to the burner assembly of the furnace 70 whereit is mixed with air and combusted to form combustion products. Thecombustion products may pass through tubes or piping in a heat exchanger(that is, separate from heat exchanger 62), such that air directed bythe blower 66 passes over the tubes or pipes and extracts heat from thecombustion products. The heated air may then be routed from the furnacesystem 70 to the ductwork 68 for heating the residence 52.

FIG. 4 is an embodiment of a vapor compression system 72 that can beused in any of the systems described above. The vapor compression system72 may circulate a refrigerant through a circuit starting with acompressor 74. The circuit may also include a condenser 76, an expansionvalve(s) or device(s) 78, and an evaporator 80. The vapor compressionsystem 72 may further include a control panel 82 that has an analog todigital (A/D) converter 84, a microprocessor 86, a non-volatile memory88, and/or an interface board 90. The control panel 82 and itscomponents may function to regulate operation of the vapor compressionsystem 72 based on feedback from an operator, from sensors of the vaporcompression system 72 that detect operating conditions, and so forth.

In some embodiments, the vapor compression system 72 may use one or moreof a variable speed drive (VSDs) 92, a motor 94, the compressor 74, thecondenser 76, the expansion valve or device 78, and/or the evaporator80. The motor 94 may drive the compressor 74 and may be powered by thevariable speed drive (VSD) 92. The VSD 92 receives alternating current(AC) power having a particular fixed line voltage and fixed linefrequency from an AC power source, and provides power having a variablevoltage and frequency to the motor 94. In other embodiments, the motor94 may be powered directly from an AC or direct current (DC) powersource. The motor 94 may include any type of electric motor that can bepowered by a VSD or directly from an AC or DC power source, such as aswitched reluctance motor, an induction motor, an electronicallycommutated permanent magnet motor, or another suitable motor.

The compressor 74 compresses a refrigerant vapor and delivers the vaporto the condenser 76 through a discharge passage. In some embodiments,the compressor 74 may be a centrifugal compressor. The refrigerant vapordelivered by the compressor 74 to the condenser 76 may transfer heat toa fluid passing across the condenser 76, such as ambient orenvironmental air 96. The refrigerant vapor may condense to arefrigerant liquid in the condenser 76 as a result of thermal heattransfer with the environmental air 96. The liquid refrigerant from thecondenser 76 may flow through the expansion device 78 to the evaporator80.

The liquid refrigerant delivered to the evaporator 80 may absorb heatfrom another air stream, such as a supply air stream 98 provided to thebuilding 10 or the residence 52. For example, the supply air stream 98may include ambient or environmental air, return air from a building, ora combination of the two. The liquid refrigerant in the evaporator 80may undergo a phase change from the liquid refrigerant to a refrigerantvapor. In this manner, the evaporator 80 may reduce the temperature ofthe supply air stream 98 via thermal heat transfer with the refrigerant.Thereafter, the vapor refrigerant exits the evaporator 80 and returns tothe compressor 74 by a suction line to complete the cycle.

In some embodiments, the vapor compression system 72 may further includea reheat coil in addition to the evaporator 80. For example, the reheatcoil may be positioned downstream of the evaporator relative to thesupply air stream 98 and may reheat the supply air stream 98 when thesupply air stream 98 is overcooled to remove humidity from the supplyair stream 98 before the supply air stream 98 is directed to thebuilding 10 or the residence 52.

It should be appreciated that any of the features described herein maybe incorporated with the HVAC unit 12, the residential heating andcooling system 50, or other HVAC systems. Additionally, while thefeatures disclosed herein are described in the context of embodimentsthat directly heat and cool a supply air stream provided to a buildingor other load, embodiments of the present disclosure may be applicableto other HVAC systems as well. For example, the features describedherein may be applied to mechanical cooling systems, free coolingsystems, chiller systems, or other heat pump or refrigerationapplications.

As discussed below, an HVAC system 100, such as the HVAC unit 12, theresidential heating and cooling system 50, and/or the vapor compressionsystem 72 may include a blower assembly 102 having a blower 104, such asthe blower assembly 34 and/or the blower 66. The blower assembly 102 maybe used to pass air over a heat exchanger, such as the heat exchangers28, 30, 60, 62, the condenser 76, and/or the evaporator 80. In someembodiments, the blower assembly 102 may be utilized to provideconditioned air to a conditioned space after passing air over the heatexchanger, or may be utilized to expel air into the atmosphere. Theblower assembly 102 further includes a motor 106, such as the motor 36,which is configured to power the blower 104. Particularly, the motor 106transfers rotational power to the blower 102 via a drive belt 108. Insome instances, the drive belt 108 may loosen over time, or losetension. Accordingly, provided herein is a belt tensioner 114 configuredto adjust a tension of the drive belt 108.

To illustrate, FIG. 5 is a perspective view of the blower assembly 102of the HVAC system 100. As discussed above, the blower assembly 102 maybe utilized to move air through the HVAC system 100, such as to provideconditioned air to a space. The blower assembly 102 includes the blower104 and the motor 106. The motor 106 is configured to transferrotational power to the blower 104 via the drive belt 108. Morespecifically, the motor 106 may cause a motor pulley 110 to rotate,thereby transferring power to the drive belt 108, which in turn drivesrotation of a blower pulley 112 of the blower 104 to rotate and driveoperation of the blower 104. The drive belt 108 may be a flat belt, atoothed belt, a V-belt, a multi-groove belt, or any other suitable beltor loop that drivingly links the motor pulley 110 and the blower pulley112.

The blower assembly 102 further includes the belt tensioner 114configured to adjust a tension of the drive belt 108. For example, insome embodiments, the drive belt 108 may be formed from a rubber, orother polymer, and may stretch or lose tension over time. Accordingly,the belt tensioner 114 may be utilized to increase or otherwise adjust atension of the drive belt 108, thereby ensuring that the drive belt 108is taught and adequately engaged with the motor pulley 110 and theblower pulley 112 to avoid slippage between the drive belt 108 and themotor pulley 110 and/or the blower pulley 112.

The belt tensioner 114 may be mounted directly to a blower housing 116of the blower assembly 102. The blower housing 116 houses the blower 104and components associated with the blower 104, such as a fan wheel 118,or a blower fan. The belt tensioner 114 is positioned on the blowerhousing 116 to be adjacent to a slack side 120 of the drive belt 108.For example, as illustrated, the motor 106 may cause the motor pulley110 to rotate in a clockwise direction 122, thereby causing the top sideof the drive belt 108 to be a tight side 124, which is in tension, andcausing the bottom side of the drive belt 108 to be the slack side 120.The belt tensioner 114 is positioned adjacent to the slack side 120 tocontact the drive belt 108 and selectively deflect the slack side 120 ofthe drive belt 108 to increase a tension of the drive belt 108 at adesired magnitude. Particularly, the belt tensioner 114 may include anidler pulley 126 configured to contact and deflect the drive belt 108.The idler pulley 126 is configured to freely rotate in response to themoving drive belt 108. Indeed, the idler pulley 126 may include an outershell formed of plastic, or another suitable material, and may include aset of bearings configured to enable rotation of the outer shell inresponse to movement of the drive belt 108.

Further, the idler pulley 126 is coupled to an idler arm 128, such as anL-shaped support or L-shaped bracket, of the belt tensioner 114. Theidler arm 128 may include an idler pulley mounting portion 130, which issubstantially L-shaped, as shown. Specifically, the idler pulleymounting portion 130 is rotatably coupled to a mounting bracket 132about a fulcrum 134, or bend, of the idler pulley mounting portion 130.Moreover, the idler pulley mounting portion 130 may include a firstportion 136, or first leg, to which the idler pulley 126 is rotatablycoupled, and a second portion 138, or second leg, disposed at an anglerelative to the first portion 136 about the fulcrum 134. In other words,the first portion 136 and the second portion 138 may be disposedcrosswise, or at an angle, relative to each other about the fulcrum 134.For example, in some embodiments, an interior angle 140 of the crosswisedisposition between the first portion 136 and the second portion 138 maybe approximately between 90° and 180°.

The belt tensioner 114 is coupled to the blower housing 116 via themounting bracket 132. More specifically, the idler arm 128 is rotatablycoupled to the mounting bracket 132 via a fulcrum fastener 142 disposedthrough the fulcrum 134, or point of rotation, or connection point, ofthe idler arm 128. The idler arm 128 is also coupled to the mountingbracket 132 via an adjustment assembly 144, or angular adjuster. Theadjustment assembly 144 is configured to adjust an angular position ofthe idler pulley 126 relative to a base 145 of the blower assembly 102in order to adjust the tension in the drive belt 108. To illustrate, theadjustment assembly 144 is coupled to the second portion 138 of theidler arm 128. Accordingly, as discussed in further detail below, theadjustment assembly 144 is configured to be operated to adjust aposition of the second portion 138, thereby causing the angular positionof the first portion 136 and the idler pulley 126 to be similarlyadjusted. For example, in certain embodiments, the adjustment assembly144 may provide a downward force on the second portion 138, therebycausing the idler pulley 126 to rotate in the counter-clockwisedirection 146. Therefore, the idler pulley 126, which is coupled to anend of the first portion 136, is similarly moved in thecounter-clockwise direction 146 towards the drive belt 108, therebyincreasing a force on the drive belt 108 and correspondingly increasinga tension of the drive belt 108.

Further, as shown and in certain embodiments, the motor 106 may bemounted to the blower housing 116 via a motor support 149 of the blowerhousing 116. Particularly, the motor 106 may be rigidly coupled to themotor support 149, which in turn is rigidly coupled to the blowerhousing 116. In other words, the motor 106 may be held stationaryrelative to the blower housing 116 without components to adjust aposition of the motor 106 relative to the blower 104. In this manner,the blower housing 116 and the motor 106 may be coupled with static, orstationary, components that are resistant to degradation, loosening,and/or wear, thereby extending an operational life of the blowerassembly 102.

The following discussion references FIGS. 6, 7, and 8, which showvarious views of the belt tensioner 114. Specifically, FIG. 6 is a frontview of the belt tensioner 114, FIG. 7 is a side view of the belttensioner 114, and FIG. 7 is an exploded perspective view of the belttensioner 114. As discussed above, the belt tensioner 114 includes themounting bracket 132, the idler pulley 126, the idler arm 128, and theadjustment assembly 144.

The mounting bracket 132 includes a top portion 150, an outer portion152, and an inner portion 154. The inner portion 154 and the outerportion 152 may be substantially parallel to each other and may both besubstantially perpendicular to the top portion 150, as shown. Further,the mounting bracket 132 may be coupled to the blower housing 116 viaone or more mounting fasteners 156. For example, as presentlyillustrated, the mounting bracket 132 includes two mounting fasteners156. Each mounting fastener 156 may include a hex rivet nut 158 and amounting bolt 160. In some embodiments, the blower housing 116 mayinclude an aperture corresponding to each mounting fastener 156.Particularly, the aperture may be a hexagon-shaped aperture configuredto receive the hex rivet nut 158. For example, the hex rivet nut 158 maybe a rivet whereby a first end 162 of the hex rivet nut 158 includes alip, or head, configured to abut against a surface of the blower housing116, while a second end 164 of the hex rivet nut 158 is configured to beset, or peened, to create a ridge, or head, to abut against an oppositesurface of the blower housing 116 once the hex rivet nut 158 is insertedwithin the aperture of the blower housing 116. The mounting bolt 160 maythen be inserted through a mounting aperture 166 disposed through theinner portion 154 of the mounting bracket 132 to rigidly couple themounting bracket 132 to the blower housing 116.

As mentioned above, the idler pulley 126 and the idler arm 128 may becoupled to the mounting bracket 132 via the fulcrum fastener 142.Particularly, as shown, the fulcrum fastener 142 may include a bolt 168,a set of washers 170, and a nut 172. The bolt 168 may extend through afulcrum aperture 174 extending through the fulcrum 134 of the idlerpulley 126 and through a rotational aperture 176 extending through theouter portion 152 of the mounting bracket 132. The nut 172 may couple tothe bolt 168 to hold the bolt 168 within the fulcrum aperture 174 andthe rotational aperture 176, thereby coupling the idler pulley 126 andthe idler arm 128 to the mounting bracket 132. As will be appreciated,the fulcrum fastener 142 may couple the idler pulley 126 and the idlerarm 128 to the mounting bracket 132 to allow rotation of the idlerpulley 126 and the idler arm 128 about the fulcrum aperture 174 and therotational aperture 176. Indeed, in some embodiments, the fulcrumfastener 142 may loosely couple the idler arm 128 to the mountingbracket 132 so as to impart minimal friction and allow the rotation ofthe idler arm 128.

The idler arm 128 may further be coupled to the mounting bracket 132 viathe adjustment assembly 144. The adjustment assembly 144 may include anadjustment bolt 180, or threaded bolt, a hex rivet nut 182, a set ofwashers 184, and a locking nut 186. The adjustment bolt 180 may extendthrough a slot 188, such as an elongated aperture or slot, disposedthrough an adjustment plate 190 of the idler arm 128. Particularly, theadjustment plate 190 may extend crosswise, such as substantiallyperpendicularly, from an edge 191 of the second portion 138 of the idlerarm 128 toward the inner portion 154 of the mounting bracket 132.Indeed, the idler pulley mounting portion 130 of the idler arm 128 maybe integrally formed with the adjustment plate 190 as one piece, such asthrough bending or welding.

The adjustment bolt 180 may further extend through the hex rivet nut182, which disposed within an aperture 192 within the top portion 150 ofthe mounting bracket 132. The hex rivet nut 182 may be similar to thehex rivet nut 158 described above in that a first end 194 of the hexrivet nut 182 includes a lip, or head, configured to abut against asurface of the top portion 150, while a second end 196 of the hex rivetnut 182 is configured to be set, or peened, to create a ridge, or head,to abut against an opposite surface of the top portion 150 once the hexrivet nut 182 is inserted within the aperture 192 of the top portion150. Further, the aperture 192 formed in the top portion 150 may becorrespondingly hexagon-shaped, thereby preventing rotation of the hexrivet nut 182 within the aperture 192. The set of washers 184 may bedisposed along the adjustment bolt 180 and on opposite sides of theadjustment plate 190, as shown. For example, a first washer of the setof washers 184 may contact an exterior side 198 of the adjustment plate190, and a second washer of the set of washers 184 may contact aninterior surface 200 of the adjustment plate 190. Further, the lockingnut 186 may be disposed adjacent to the second washer and along theadjustment bolt 180. Accordingly, the locking nut 186 may be torquedalong the adjustment bolt 180 towards a bolt head 202 of the adjustmentbolt 180 to capture the washers 184 and adjustment plate 190 between thelocking nut 186 and the bolt head 202. In this manner, the adjustmentbolt 180 and the adjustment plate 190 of the idler arm 128 are held in afixed position relative to one another, thereby locking the angularorientation of the idler arm 128.

In operation, rotation of the adjustment bolt 180 about a longitudinalaxis of the adjustment bolt 180 may cause the idler pulley 126 toincrease or decrease tension on the drive belt 108, depending on thedirection of rotation of the adjustment bolt 180. For example, as mostclearly seen in FIG. 6, rotating the adjustment bolt 180 to thread theadjustment bolt 180 further into the hex rivet nut 182, as indicated byarrow 204, causes the adjustment bolt 180 to impart the clockwiserotation 122 on the idler pulley 126 via the adjustment plate 190 andthe idler arm 128. Correspondingly, rotating the adjustment bolt 180 tothread the adjustment bolt 180 further out of the hex rivet nut 182, asindicated by arrow 206, causes the adjustment bolt 180 to impart acounter-clockwise rotation 146 on the idler pulley 126 via theadjustment plate 190 and the idler arm 128.

In some embodiments, as the adjustment bolt 180 and the idler pulley 126are adjusted, the adjustment bolt 180 may move within the slot 188 ofthe adjustment plate 190. In other words, the adjustment plate 190 maymove relative to the adjustment bolt 180 via the slot 188 having theadjustment bolt 180 extending therethrough. For example, during rotationof the idler pulley 126 and the idler arm 128 in the clockwise direction122, the position of the adjustment bolt 180 is adjusted within the slot188 in a direction toward the fulcrum 134. Similarly, during rotation ofthe idler pulley 126 and the idler arm 128 in the counter-clockwisedirection 146, the position of the adjustment bolt 180 is adjustedwithin the slot 188 in a direction away from the fulcrum 134. Indeed,the movement of the adjustment bolt 180 within the slot 188 may becaused at least in part by the linear movement of the adjustment bolt180 relative to the rotational motion of the idler arm 128. Moreover, incertain embodiments, the locking nut 186 may be loosened, such astorqued away from the bolt head 202, prior to adjustment of the idlerarm 128 to enable the movement of the adjustment bolt 180 within theslot 188. Once the adjustment bolt 180 and the idler arm 128 have beenadjusted to a desired orientation, the locking nut 186 may be tightened,such as torqued toward the bolt head 202, to secure the idler arm 128 ina stationary position relative to the adjustment bolt 180.

As shown above in FIG. 5 and described above, the clockwise rotation 122of the idler arm 128 may cause the idler pulley 126 to decrease a forceon the drive belt 108, and a counter-clockwise rotation 146 of the idlerarm 128 may cause the idler pulley 126 to increase a force on the drivebelt 108. However, it should be understood that the clockwise 122 andcounter-clockwise 146 directions may optionally increase or decrease aforce on the drive belt 108, depending on an orientation and position ofthe belt tensioner 114 relative to the drive belt 108. For example, insome embodiments, the belt tensioner 114 may be disposed approximately90 counter-clockwise 146 from its currently illustrated position in FIG.5. In such embodiments, clockwise rotation 122 of the idler arm 128 maycause the idler pulley 126 to increase a force on the drive belt 108,and counter-clockwise rotation 146 of the idler arm 128 may cause theidler pulley 126 to decrease a force on the drive belt 108. Indeed, itis to be understood that the belt tensioner 114 may be oriented andpositioned at any suitable orientation and position relative to thedrive belt 108, which, in some embodiments, may change an operation ofthe belt tensioner 114, as described above. However, in such alternativeembodiments, the belt tensioner 114 may still be secured to the blowerhousing 116 or other stationary component of the blower assembly 102 toenable tension adjustment of the drive belt 108 without adjustment ofthe motor 106 or blower 104 relative to one another. In this manner,embodiments of the belt tensioner 114 disclosed herein enable a moresimple, efficient, and convenient adjustment of tension in the drivebelt 108.

In some embodiments, the belt tensioner 114 may experience a jerk, orsudden and momentary force, from the drive belt 108, such as when theblower assembly 102 commences operation. Accordingly, FIG. 9 is aperspective view of an embodiment of the belt tensioner 114, whichincludes a spring 208 to enable deflection of the idler arm 128 inresponse to the initial jerk or movement of the drive belt 108. In thismanner, an operational life of the drive belt 108 may be extended. Forexample, as shown in the illustrated embodiment, the spring 208 may bedisposed about the adjustment bolt 180 of the adjustment assembly 144.More specifically, the spring 208 may be disposed along the adjustmentbolt 180 in between the locking nut 186 and the adjustment plate 190 ofthe idler arm 128. As shown, the adjustment assembly 144 may furtherinclude respective washers 210 directly adjacent to both longitudinalends of the spring 208 along the adjustment bolt 180. In operation, whenthe idler pulley 126 of the idler arm 128 is in contact with the drivebelt 108, the drive belt 108 may impart a force on the idler pulley 126.The force experienced by the idler pulley 126 may cause the idler arm128 to rotate, as described above. Accordingly, the rotation of theidler arm 128 may cause the adjustment plate 190 to move generallytoward the top portion 150 of the mounting bracket 132, thereby causingthe spring 208 to compress to absorb some of the force imparted by thedrive belt 108. In other words, the spring 208 may bias the adjustmentplate 190 away from the mounting bracket 132. In this manner, the forceof the initial jerk or movement of the drive belt 108 may be transferredto the spring 208, as opposed to a stationary object that may not absorbthe force as readily, thereby increasing the operational life of thedrive belt 108. Moreover, during general operation of the blowerassembly 102, the drive belt 108 may experience fluctuations orinconsistencies in a movement of the drive belt 108 along the motorpulley 110 and/or the blower pulley 112. For example, the drive belt 108may vibrate while in operation. Accordingly, the spring 208 maysimilarly absorb forces of the fluctuations of the drive belt 108,thereby extending an operational life of the drive belt 108.

As mentioned above, the adjustment plate 190 of the idler arm 128 maytravel along different motion paths relative to the adjustment bolt 180of the adjustment assembly 144. Specifically, the adjustment plate 190may move relative to the adjustment bolt 180 along a substantiallycircular path, while the adjustment bolt 180 may move relative to theadjustment plate 190 along a substantially linear path. Indeed, asdescribed above, the adjustment bolt 180 may be rotated, orthreaded/unthreaded relative to the hex rivet nut 182, to be linearlydisplaced and cause the idler arm 128 to rotate. In some embodiments,the disparate motions paths of the adjustment bolt 180 and theadjustment plate 190 may cause the adjustment bolt 180 and/or theadjustment plate 190 to experience a bending moment or force.

Accordingly, in certain embodiments and as shown in FIG. 10, theadjustment bolt 180 may abut the interior surface 200 of the adjustmentplate 190 of the idler arm 128. In this manner, the adjustment plate 190and/or the adjustment bolt 180 may not experience the bending momentduring operation, as described above. In other words, a bending forcemay not transfer between the adjustment plate 190 and the adjustmentbolt 180. For example, in the illustrated embodiment, the bolt head 202of the adjustment bolt 180 may be disposed external to the top portion150 of the mounting bracket 132 and the hex rivet nut 182. Further, theadjustment plate 190 of the idler arm 128 may be substantially solid,such as without the slot 188 shown in FIGS. 6-9. In this manner, adistal end 212 of the adjustment bolt 180 may abut, and apply a force,on the interior surface 200 of the adjustment plate 190 when the idlerpulley 126 is in contact with the drive belt 108. In this manner,rotation of the adjustment bolt 180 about the longitudinal axis of theadjustment bolt 180 to thread the adjustment bolt 180 further into thehex rivet nut 182, which causes the adjustment bolt 180 to traveltowards the adjustment plate 190, may cause the idler pulley 126, totravel generally in a direction into the page, as denoted by the vectorsymbol 214. Correspondingly, rotation of the adjustment bolt 180 aboutthe longitudinal axis of the adjustment bolt 180 to unthread theadjustment bolt 180 out of the hex rivet nut 182, which causes theadjustment bolt 180 to retract away from the adjustment plate 190, mayallow the drive belt 108 to force the idler pulley 126 to travelgenerally in a direction out of the page, as denoted by the vectorsymbol 216.

Further, in certain embodiments and as shown in FIG. 11, the adjustmentassembly 144 may include a hemispherical cup 218 and a hemisphericalwasher 220 to enable adjustment of an angular position of the adjustmentbolt 180 relative to the hemispherical cup 218 and relative to themounting bracket 132. Indeed, it should be understood that, in someembodiments, the hemispherical cup 218 and the hemispherical washer 220may generally be curved, such as having a degree of curvature that ismore or less than a hemisphere of a sphere. As shown in FIG. 11, theadjustment assembly 144 may further include a nut 222 and a washer 224disposed along the adjustment bolt 180 between the distal end 212 of theadjustment bolt 180 and the hemispherical washer 220. First, it shouldbe noted that the hemispherical washer 220 and the hemispherical cup 218are both illustrated as cross-sectional views. Indeed, it should beunderstood that both the hemispherical washer 220 and the hemisphericalcup 218 may extend 360 degrees about the adjustment bolt 180. In thismanner, the adjustment plate 190 and/or the adjustment bolt 180 may notexperience a bending moment during operation, as described above.

Further, as also described above with reference to FIGS. 6-8, when thebelt tensioner 114 is adjusted, the adjustment bolt 180 may relativelymove within the slot 188 formed in the adjustment plate 190 of the idlerarm 128. Moreover, in the embodiments of FIGS. 6-8, as the adjustmentbolt 180 relatively moves within the slot 188, the adjustment bolt 180may be disposed at an angle, such as greater than or less than 90degrees relative to the interior surface 200 of the adjustment plate190. This may cause an inefficient application of forces because theadjustment bolt 180 may apply a force at an angle relative to thetangential direction of the rotational motion of the adjustment plate190. In the illustrated embodiment of FIG. 11, however, thehemispherical cup 218 and the hemispherical washer 220 may enable theadjustment bolt 180 to be angularly displaced in conjunction withrotational motion of the adjustment plate 190. In this manner, theadjustment bolt 180 may rotate with the adjustment plate 190 and theidler arm 128, such that the adjustment bolt 180 may be disposed normalto the interior surface 200 of the adjustment plate 190. Particularly,in certain embodiments, a curvature of the hemispherical washer 220 maysubstantially match a curvature of the hemispherical cup 218. In thismanner, the hemispherical washer 220 and the adjustment bolt 180 maymove in conjunction relative to the hemispherical cup 218, therebyenabling the adjustment bolt 180 to move within a conical area 230 ofmotion. The conical area 230 of motion may have an angle ofapproximately 15 degrees, for example, or any other suitable anglerelative to a vertex of the conical area 230. The normal orperpendicular orientation of the adjustment bolt 180 relative to theinterior surface 200 of the adjustment plate 190 may enable theadjustment bolt 180 to apply a force in the tangential direction of therotational motion of the adjustment plate 190, thereby enablingefficient application of force to the idler arm 128 to adjust ormaintain the orientation of the idler arm 128.

Additionally, in some embodiments, the belt tensioner 114 may include anarcuate slot 228 to enable adjustment of the idler arm 128, the idlerpulley 126, and the tension of the drive belt 108. For example, as shownin FIGS. 12 and 13, the belt tensioner 114 may include the arcuate slot228 in the second portion 138 of the idler arm 128 to enable rotationaladjustment of the idler arm 128 relative to the mounting bracket 132.The mounting bracket 132 may be coupled to the blower housing 116 viathe mounting fasteners 156, as described above. Specifically, in theillustrated embodiment of FIG. 12, the mounting bracket 132 includes afirst mounting adjustment flange 231 and a second mounting adjustmentflange 232, each configured to receive two mounting fasteners 156 tocouple the first mounting adjustment flange 231 and the second mountingadjustment flange 232 to the blower housing 116. Moreover, similar tothe embodiments discussed above, the idler arm 128 may be coupled to thetop portion 150 of the mounting bracket 132 via the fulcrum fastener 142extending through the fulcrum 134 of the idler arm 128.

In the illustrated embodiments of FIGS. 12 and 13, the adjustmentassembly 144 includes an arcuate slot fastener 234 extending through thearcuate slot 228 of the second portion 138 of the idler arm 128. Thearcuate slot fastener 234 extends through the arcuate slot 228 andthrough an aperture 236 formed in the top portion 150 of the mountingbracket 132. The arcuate slot fastener 234 includes a bolt 238, a washer240, and a nut 242. The nut 242 may be coupled to the bolt 238 on aninterior side 244 of the mounting bracket 132. The washer 240 may bedisposed along the bolt 238 in between the bolt head 246 and the topportion 150 of the mounting bracket 132. In operation, the arcuate slotfastener 234 may be loosened, such as through rotation of the nut 242.Once the arcuate slot fastener 234 is loosened, the idler arm 128 may berotated about the fulcrum 134, such as via direct manipulation of theidler arm 128. Once the idler arm 128 is at a desired position, orangular orientation, the arcuate slot fastener 234 may be tightened,thereby capturing the second portion 138 of the idler arm 128 and thetop portion 150 of the mounting bracket 132 and holding the idler arm128 and the idler pulley 126 in the desired angular orientation.

In some embodiments, portions of the belt tensioner 114 may beconfigured to adjust in a linear direction to adjust the tension in thedrive belt 108. For example, FIG. 14 is a side view of the blowerassembly 102 having an embodiment of the belt tensioner 114 mounted tothe blower housing 116, as similarly described above. In the illustratedembodiment, an idler pulley assembly 250 of the belt tensioner 114 isconfigured to be linearly repositioned to adjust the tension in thedrive belt 108.

As shown, the belt tensioner 114 includes the idler pulley assembly 250,which includes an idler pulley 251 configured to engage with the drivebelt 108 to adjust a tension in the drive belt 108. The idler pulleyassembly 250 is mounted to an idler mounting plate 252. The idlermounting plate 252 is configured to move linearly within a guide rail254 of the belt tensioner 114. That is, the guide rail 254 is configuredto guide the idler mounting plate 252 to move substantially linearlyalong a guide path, and the belt tensioner 114 is configured to retain aposition of the idler mounting plate 252 at a selected position to applya desired tension on the drive belt 108. The guide rail 254 is mounteddirectly to the blower housing 116 via a set of mounting fasteners 256,such as bolts and/or screws, extending through mounting flanges 258 ofthe guide rail 254. Particularly, as shown in the illustratedembodiment, the guide rail 254 may include two mounting flanges 258extending along a surface of the blower housing 116 in a mountedconfiguration. Each mounting flange 258 is configured to receive one ormore, such as two, mounting fasteners 256 to couple the guide rail 254to the blower housing 116. Accordingly, the idler pulley assembly 250and the idler mounting plate 252 are configured to be linearly adjustedrelative to the blower housing 116 and the guide rail 254 to adjust adegree to which the idler pulley 251 imparts a force on the drive belt108 to adjust tension in the drive belt 108.

The belt tensioner 114 further includes a lock plate 260 and a bolt 262.The lock plate 260 is also mounted directly to the blower housing 116.The bolt 262 extends through the lock plate 260 and through a flange ofthe idler mounting plate 252, as discussed in further detail below. Thebolt 262 is configured to be rotated about a longitudinal axis 264 ofthe bolt 262 to linearly adjust a position of the idler pulley assembly250. That is, rotation of the bolt 262 about its longitudinal axis 264causes a linear position of the bolt 262 to be adjusted relative to thelock plate 260 and the guide rail 254. At the same time, a linearposition of the bolt 262 is maintained relative to the idler mountingplate 252 during rotation of the bolt 262 about its longitudinal axis264. In other words, the bolt 262 and the idler mounting plate 252 arefixed to one another, such that linear movement of the bolt 262 causescorresponding linear movement of the idler mounting plate 252 and theidler pulley 251. Therefore, rotation of the bolt 262 about itslongitudinal axis 264 causes the idler mounting plate 252 to be linearlyadjusted, thereby similarly adjusting a linear position of the idlerpulley 251 to adjust the tension in the drive belt 108.

To further illustrate, the bolt 262 may be rotated in a first direction,such as clockwise, about the longitudinal axis 264 to cause the idlerpulley 251 to move linearly toward the drive belt 108, as indicated byarrow 266. When the idler pulley 251 is in contact with the drive belt108 and moving in the direction 266, the tension in the drive belt 108may increase. Similarly, the bolt 262 may be rotated in a seconddirection, such as counter-clockwise, about the longitudinal axis 264 tocause the idler pulley 251 to move linearly away from the drive belt108, as indicated by arrow 268. When the idler pulley 251 is in contactwith the drive belt 108 and moving in the direction 268, the tension inthe drive belt 108 may decrease. Indeed, in some embodiments, the idlerpulley 251 may be positioned such that it is not in contact with thedrive belt 108. Accordingly, the idler pulley 251 may be positioned tocontact the drive belt 108 with a desired force to affect or adjust thetension in the drive belt 108.

As shown, in the current embodiment, the belt tensioner 114 ispositioned such that the idler pulley 251 is disposed external to aninterior region 270 defined by the drive belt 108. Thus, with the idlerpulley 251 positioned external to or outside of the interior region 270,the idler pulley 251 is configured to contact an exterior edge orsurface 272 of the drive belt 108 to adjust tension in the drive belt108. However, in some embodiments, the belt tensioner 114 may bepositioned such that the idler pulley 251 is disposed within theinterior region 270. In such embodiments, the idler pulley 251 isconfigured to contact an interior edge or surface 274 of the drive belt108 to adjust tension in the drive belt 108.

FIGS. 15 and 16 are perspective views of an embodiment of the belttensioner 114. More specifically, the perspective view shown in FIG. 15more clearly shows an outside-facing portion of the belt tensioner 114,relative to the blower housing 116 when belt tensioner 114 is coupled tothe blower housing 116. The perspective view shown in FIG. 16 moreclearly shows an inside-face portion of the belt tensioner 114, relativeto the blower housing 116 when the belt tensioner 114 is coupled to theblower housing 116. FIGS. 15 and 16 will are discussed in parallelbelow. As shown, the belt tensioner 114 includes the idler pulleyassembly 250, which is mounted to the idler mounting plate 252. Theidler mounting plate 252 is configured to move, such as by sliding,linearly within the guide rail 254. As mentioned above, the belttensioner 114 also includes the bolt 262 extending through the lockplate 260 and through a flange 278 of the idler mounting plate 252.

The lock plate 260 includes a mounting portion 282 or flange and alocking portion 284 or flange. In some embodiments, the mounting portion282 may extend substantially perpendicular from and relative to thelocking portion 284, as shown. The mounting portion 282 may be coupledto the blower housing 116 via a fastener, such as a bolt or screw, whichextends through a first aperture 286 formed in the mounting portion 282.A second aperture 289 extends through the locking portion 284 of thelock plate 260 and is configured to receive a nut 280, such as a clenchnut or swage nut. That is, the nut 280 is configured to be press fit orcold worked into the second aperture 289 to couple the nut 280 to thelock plate 260 and be held rotationally stationary relative to thesecond aperture 289. Particularly, the nut 280 may include teeth orridges that are configured to engage with a surface of the mountingportion 284 defining a perimeter of the second aperture 289. In someembodiments, the nut 280 may be any suitable fastener configured to beheld rotationally still within or adjacent to the aperture 290. Forexample, the nut 280 may be a hexagonal rivet nut, and the secondaperture 289 may be hexagonally-shaped to receive the hexagonal rivetnut. The nut 280 includes internal threads with which correspondingthreads of the bolt 280 may engage. In some embodiments, the lock plate260 may include any suitable threaded element that provides a threadedsurface about the second aperture 289, such as the nut 280. In certainembodiments, the lock plate 260 may include a threaded surfaceintegrally formed with the second aperture 289. Accordingly, the bolt262 extends through the second aperture 289 and engages with a threadedsurface, such as threads of the nut 280, such that rotation of the bolt280 causes the bolt 262 to be linearly adjusted relative to and throughthe second aperture 289.

As mentioned above, the bolt 262 also extends through the flange 278 ofthe idler mounting plate 252. Particularly, the bolt 262 extends througha third aperture 291 that is disposed through the flange 278. The bolt262 may rotate freely within the third aperture 291 of the flange 278.The bolt 262 bolt is also held linearly stationary relative to theflange 278. To this end, the belt tensioner 114 may include a fasteningsystem, such as a pair of locking nuts 294, disposed along the thread ofthe bolt 262 with the flange 278 disposed between the two locking nuts294. The pair of locking nuts 294 may be more clearly viewed in FIG. 17.A distance between the two locking nuts 294 along the shaft of the bolt262 may be slightly larger than a thickness of the flange 278.Particularly, the two locking nuts 294 may be positioned along the bolt262, such that the two locking nuts 294 prevent substantial linearmovement of the bolt 262 relative to the flange 278 while allowing thebolt 262 to rotate relative to the flange 278.

The belt tensioner 114 further includes a locking assembly 290configured to selectively lock or fix a linear position of the idlermounting plate 252 relative to the guide rail 254. The locking assembly290 includes a first fastener 292 and a second fastener 293. The lockingassembly 290, and more specifically, the first fastener 292 and thesecond fastener 293, may be engaged, such as via torqueing, to lock aposition of the idler mounting plate 252 relative to the guide rail 254.Similarly, the locking assembly 290 may be disengaged, such as viatorqueing, to enable linear movement of the idler mounting plate 252relative to the guide rail 254. As discussed in further detail below,the first fastener 292 and the second fastener 293 may both extendthrough slots 296 disposed through guide rail 254 and through holes 297disposed through the idler mounting plate 252. In some embodiments, thefirst fastener 292 and the second fastener 293 may each extendsubstantially perpendicularly relative to the longitudinal axis 264. Asthe idler mounting plate 252 and the idler pulley 251 are translatedlinearly in response to rotation of the bolt 262, as discussed above,the first fastener 292 and the second fastener 293 may be translatedwithin respective slots 296 of the guide rail 254. Accordingly, lengthsof the slots 296 may provide a limit to the linear distance for whichthe idler mounting plate 252 may travel within the guide rail 254.

For example, as discussed in further detail below with reference toFIGS. 18 and 19, the idler mounting plate 252 and the idler pulley 251may travel between a first boundary position and a second boundaryposition. The linear positional difference between the first boundaryposition and the second boundary position may be equal to the length ofthe slots 296. The locking assembly 290 may be engaged to lock the idlermounting plate 252 at the first boundary position, at the secondboundary position, or at a position between the first and secondboundary positions.

FIG. 17 is an exploded perspective view of an embodiment of the belttensioner 114. As shown, the belt tensioner 114 includes the lock plate260, the idler pulley assembly 250, the idler mounting plate 252, thelocking assembly 290, the guide rail 254, and the bolt 262.

As discussed above, the lock plate 260 includes the mounting portion 282and the locking portion 284 and may be formed as a single piece. Themounting portion 282 may be disposed substantially perpendicularlyrelative to the locking portion 284. The mounting portion 282 includesthe first aperture 286 configured to receive a fastener to couple thelocking plate 260 to the blower housing 116. The locking portion 284includes the second aperture 289 configured to receive and secure thenut 280. Indeed, as mentioned above, the nut 280 may be coupled to thesecond aperture 289, such that the nut 280 is held rigidly relative tothe second aperture 289. In other embodiments, the locking portion 284may include any suitable threaded surface configured to engage threadsof the bolt 262 about the second aperture 289.

The bolt 262 extends through the lock plate 260 and engages with threadsof the nut 280 or other threaded surface. The bolt 262 also extendsthrough the flange 278 of the idler mounting plate 252 and engages withthreads of the pair of locking nuts 294. To illustrate, a first lockingnut 300 of the pair of locking nuts 294 may be disposed along the shaftof the bolt 262 adjacent to a first side 302 of the flange 278. Further,a second locking nut 304 of the pair of locking nuts 294 may be disposedalong the shaft of the bolt 262 adjacent to a second side 306 of theflange 278. The pair of locking nuts 294 may hold a linear position ofthe bolt 262, along the longitudinal axis 264, substantially fixedrelative to the flange 278 while enabling rotation of the bolt 262relative to the flange 278 about the longitudinal axis 264.

For example, during rotation of the bolt 262 to cause the bolt 262 tomove in the direction 266, the bolt 262 rotates within the aperture 291of the flange 278, and the first locking nut 300 of the locking nuts 294may contact the flange 278 and push the flange 278 in the direction 266,while the second locking nut 304 of the locking nuts 294 may be spacedslightly apart from the flange 278. Similarly, during rotation of thebolt 262 to cause the bolt 262 to move in the direction 268, the secondlocking nut 304 may contact the flange 278 and pull the flange 278 inthe direction 268 while the first locking nut 300 is spaced slightlyapart from the flange 278. Accordingly, in this configuration, thelocking nuts 294 are configured to substantially block linear movementof the bolt 262 relative to the flange 278 and enable rotationalmovement of the bolt 262 within the aperture 291 of the flange 278.

The idler mounting plate 252 includes the flange 278, an outward-facingportion 310, a first lateral portion 312, and a second lateral portion314. As shown, the first and second lateral portions 312, 314 may besubstantially parallel relative to each other. The outward-facingportion 310 may extend between the first and second lateral portions312, 314 and may be disposed substantially perpendicularly relative tothe first and second lateral portions 312, 314. The flange 278 may bedisposed at a first end 316 of the idler mounting plate 252 and mayextend between the outward-facing portion 310 and the first and secondlateral portions 312, 314. The flange 278 may be disposed substantiallyperpendicularly relative to the outward-facing portion 310 and the firstand second lateral portions 312, 314. A second end 318, disposedopposite of the first end 316, of the idler mounting plate 252 may besubstantially open, such that the second end 318 does not include aflange, such as the flange 278. In other words, the idler mounting plate252 may be a U-bracket which is closed at the first end 316 via theflange 278.

The idler pulley assembly 250 is coupled to the outward-facing portion310 of the idler mounting plate 252. The idler pulley assembly 250includes an idler bolt 320, a first bushing 322, the idler pulley 251, asecond bushing 324, and a nut 326. As shown, the idler bolt 320 extendsthrough a hole 328 disposed through the outward-facing portion 310. Theidler bolt 320 may further extend through holes or bores of each of thefirst bushing 322, the idler pulley 251, the second bushing 324, and thenut 326, sequentially as shown. The first and second bushings 322, 324may help to absorb forces experienced by the idler pulley 251 from thedrive belt 108. For example, in some embodiments, such as the embodimentshown in FIG. 15, the first and second bushings 322, 324 may be disposedaxially between the idler pulley 251 and the idler bolt 320, relative toa longitudinal axis of the idler bolt 320, such that the idler pulley251 is in contact with the first and second bushings 322, 324 and not incontact with the bolt 320, thereby decreasing an amount of force that istransferred from the idler pulley 251 to the idler bolt 230. The firstbushing 322 may also reduce or eliminate contact between the idlerpulley 251 and the idler mounting plate 252 and the guide rail 254 toreduce friction therebetween. In some embodiments, the idler pulley 251may include one or more bearings configured to further reduce frictionexperienced during rotation of the idler pulley 251 when the idlerpulley 251 is in contact with the drive belt 108. The nut 326 may be alock nut that is configured to resist loosening from torque orvibrations. For example, the nut 326 may include a portion, such as anelastic insert, that is configured to plastically deform to engage withthe threads of the idler bolt 320 and provide a locking engagementbetween the idler bolt 320 and the nut 326. Further, as discussed above,the idler mounting plate 252 may be disposed internal to the guide rail254, the idler pulley 251 may be disposed external to the guide rail254, and the idler bolt 320 may extend between the idler mounting plate252 and the idler pulley 251 in an assembled configuration of the belttensioner 114.

The first lateral portion 312 and the second lateral portion 314 of theidler mounting plate 252 may each include two holes 330 configured toreceive the first and second fasteners 292, 293 of the locking assembly290. However, it is to be understood that the first and second lateralportions 312, 314 may each include any suitable number of holes 330configured to receive any suitable respective number of fasteners of thelocking assembly 290. The first and second fastener 292, 293 may alsoextend through the slots 296 of the guide rail 254, as discussed above.

Particularly, a first side portion 332 and a second side portion 333 ofthe guide rail 254 may each include two of the slots 296 discussedabove. As shown, the first side portion 332 and the second side portion333 may both extend substantially perpendicularly from mounting flanges258. Indeed, the first and second side portions 332, 333 may also besubstantially parallel relative to each other. However, it is to beunderstood that in some embodiments, the first and second side portions332, 333 may be disposed at any suitable angle relative to each otherand relative to the mounting flanges 258. Further, it is to beunderstood that the first and second side portions 332, 333 may includeany suitable number of slots 296, which may correspond to any suitablenumber of fasteners of the locking assembly 290. The guide rail 254 mayfurther include an outward-facing portion 334. The outward-facingportion 334 may include a connecting portion 336, which extends betweenand couples the first and second side portions 332, 333. As shown, theconnecting portion 336 is disposed substantially at an end 338 of theoutward-facing portion 334 and a majority of the outward-facing portion334 of the guide rail 254 may be substantially open such as to enablelinear movement of the idler pulley assembly 250 through theoutward-facing portion 334. Indeed, the outward-facing portion 334 mayfurther include a guide portion 337, as discussed in further detailbelow.

The first and second fasteners 292, 293 of the locking assembly 290 mayeach include a bolt 340, a pair of washers 342, and a nut 344. As shown,the bolt 340 sequentially extends through one of the washers 342,through one of the slots 296 of the first side portion 332 of the guiderail 254, through one of the holes 330 of the first lateral portion 312of the idler mounting plate 252, through one of the holes 330 of thesecond lateral portion 314 of the idler mounting plate 252, through oneof the slots 296 of the second side portion 333 of the guide rail 254,through one of the washers 342, and through the nut 344. Accordingly,the locking assembly 290 is configured to be tightened, such as viatorqueing of the bolt 340 and/or the nut 344, to fix a position of theidler mounting plate 252 relative to the guide rail 254, such that thebelt tensioner 114 is in a locked configuration. Specifically, in thelocked configuration, the washers 342 may apply a pressure to externalsurfaces 350 of the first and second side portions 332, 333 of the guiderail 254 to block movement of the idler mounting plate 252 relative tothe guide rail 254. The locking assembly 290 is also configured to beloosened in a similar fashion, such as by torqueing the bolt 340 and/orthe nut 344 in an opposite direction to the tightening direction.Particularly, the locking assembly 290 may be loosened such that thebelt tensioner 114 is in an unlocked configuration, thereby enablingmovement of the idler mounting plate 252 relative to the guide rail 254via rotation of the bolt 262.

As discussed herein, the idler mounting plate 252 is configured to movewithin the guide rail 254. To this end, in some embodiments, the contourof an external surface 352 or edge of the idler mounting plate 252 maysubstantially match the contour of an internal surface 354 or edge ofthe guide rail 254. The external surface 352 of the idler mounting plate252 may be defined by external surfaces of the first lateral portion312, the second lateral portion 314, and the outward-facing portion 310of the idler mounting plate 252. The internal surface 354 of the guiderail 254 may be defined by internal surfaces of the first side portion332, the second side portion 333, and the outward-facing top portion334. Further, the internal surface 354 may define an interior region 355of the guide rail 254. Keeping this in mind, the outward-facing portion334 of the guide rail 254 may include the guide portion 337 throughwhich the idler pulley assembly 250 may translate during positionaladjustment of the belt tensioner 114. Edges of the guide portion 337 maybe defined by guides 360. Specifically, the guide rail 254 may includetwo guides 360, such as flanges or lips, which extend from the first andsecond side portions 332, 333 toward an opening 361 of the guide portion337. In some embodiments, the guides 360 may extend substantiallyperpendicularly from the first and second side portions 332, 333, or inany other suitable direction to match the contour of the externalsurface 352 of the idler mounting plate 252. Accordingly, while theidler mounting plate 252 moves within the guide rail 254, the guides 360may restrain the idler mounting plate 252 from moving outward and beyondthe outward-facing portion 334 of the guide rail 254.

Further, because the mounting flanges 258 may be mounted to the blowerhousing 116, the blower housing 116 may restrain the idler mountingplate 252 from moving outwardly away from the outward-facing portion 334of the guide rail 254. In some embodiments, the guide rail 254 mayinclude a bottom surface 362 against which the idler mounting plate 252may be supported to prevent outward motion of the idler mounting plate252. Further, in some embodiments, outward motion, such as movementtowards or away from the top portion 334 may be prevented throughsupport of the locking assembly 290 via the slots 296. That is, theidler mounting plate 252 may not necessarily contact the blower housing116, the guides 360, and/or the bottom surface 362 during operation ofthe belt tensioner 114.

The guide rail 254 and the idler pulley assembly 250 may be configuredto move substantially parallel to the longitudinal axis 264 to adjusttension in the drive belt 108. Particularly, as illustrated in FIGS. 18and 19, the belt tensioner 114 may be adjusted between a first position370, such as a first boundary position or a fully retracted position,and a second position 372, such as a second boundary position or a fullyextended or engaged position. That is, FIG. 18 shows the belt tensioner114 in the first position 370, and FIG. 19 shows the belt tensioner 114in the second position 372. The belt tensioner 114 may be positioned atany location along the guide rail 254 between the first position 370 andthe second position 372 to adjust a tension in the drive belt 108.

As shown, positioning of the belt tensioner 114 at or between the firstand second positions 370, 372 may cause certain components to move whileothers are held stationary. For example, torqueing of the bolt 262 tocause the belt tensioner 114 to move between the first and secondpositions 370, 372 causes the bolt 262, the idler mounting plate 252,the locking assembly 290, and the idler pulley assembly 250 to movealong the longitudinal axis 264 and relative to the lock plate 262 andthe guide rail 254. Indeed, the lock plate 262 and the guide rail 254may be mounted directly rigidly to the blower housing 116 and may notmove during positional adjustment of the belt tensioner 114.

In the first position 370, the flange 278 of the guide rail 252 may be afirst distance 374 away from the lock plate 262, measured along thelongitudinal axis 264. In the second position 372, the flange 278 of theguide rail 252 may be a second distance 376 away from the lock plate262, measured along the longitudinal axis 264. Further, the slots 296 ofthe guide rail 254 may have or be associated with a length 378. Adifference between the first distance 374 and the second distance 376may be approximately equal to the length 378 of the slots 296. Morespecifically, the difference between the first distance 374 and thesecond distance 376 may be substantially equal to the length of theslots 296 minus the cumulative diameter of the bolts 340 of the lockingsystem 290. In other words, the distance between the first position 370and the second position 372 may be limited by the distance to which thebolts 340 of the locking system 290 may travel within the slots 296.

In some embodiments, the belt tensioner 114 may be configured toautomatically adjust tension in the drive belt 108 via a set of springs.For example, FIG. 20 is a front view of an embodiment of the belttensioner 114 mounted to the blower housing 116, as similarly describedabove. In the illustrated embodiment, an idler pulley assembly 400 isconfigured to adjust a tension in the drive belt 108 via a set ofsprings 402. The springs 402 may be linearly actuated, such that thesprings 402 are configured to compress or elongate in a substantiallylinear direction in response to a reactive load applied to the idlerpulley assembly 400 through contact of the idler pulley assembly 400with the drive belt 108. The springs 402 enable an active distributionof load between the springs 402, thereby increasing a longevity of thesprings 402 and of the belt tensioner 114. In other words, the loadapplied to the idler pulley assembly 400 via the drive belt 108 isactively distributed amongst the springs 402, which enables automaticload distribution and increases longevity of the belt tensioner 114 andthe drive belt 108.

As shown, the idler pulley assembly 400 includes an idler pulley 404configured to engage with the drive belt 108 to adjust a tension in thedrive belt 108. The idler pulley 404 is mounted to an idler arm 406 ofthe belt tensioner 114 at a distal end 407 of the idler arm 406. Theidler arm 406 is coupled to a mounting bracket 408 at a pivot point 410,which defines a pivot axis of the idler arm 406. The pivot point 410 maybe disposed at an opposite end of the idler arm 406 relative to thedistal end 407. The idler arm 406 and the idler pulley 404 areconfigured to rotate about the pivot point 410 as the idler pulleyassembly 400 reacts to a load imparted by the drive belt 108.Particularly, a pivot fastener 420 may couple the idler arm 406 to themounting bracket 408 at the pivot point 410, such that the idler arm 406and the idler pulley 404 are configured to rotate about the pivotfastener 420. The idler arm 406 is further coupled to the mountingbracket 408 via the springs 402. The springs 402 may include a tensionspring 422, or a first spring, and a compression spring 424, or a secondspring. Both the tension spring 422 and the compression spring 424extend between respective sides of the idler arm 406 and respectiveportions of the mounting bracket 408. Particularly, the tension spring422 may be coupled to a first side 430 of the idler arm 406 and to afirst arm extension 432 of the mounting bracket 408. Similarly, thecompression spring 424 may be coupled to a second side 434 of the idlerarm 406 and to a second arm extension 436 of the mounting bracket 408.

As discussed herein, a resting length of the tension spring 422, such aswhen a length of the tension spring 422 is not in an adjusted state inresponse to a load, may be defined when passes of the coil of thetension spring 422 are substantially in contact with one another or in acompressed state. Accordingly, in some embodiments, the tension spring422 may be actuated via elongation from its resting length to provide apredictable reactive force. Indeed, in some embodiments, compression ofthe tension spring 422 from its resting length may result in anunpredictable reactive force. In some embodiments, the tension spring422 may be defined by a spring of the springs 402 being in tension whenthe belt tensioner 144 is installed and engaged with the drive belt 108,as described herein. Further, a resting length of the compression spring424, such as when a length of the compression spring 424 is not in anadjusted state in response to a load, may be defined when passes of thecoils of the compression spring 424 are spaced apart from each other orin an expanded state. Accordingly, in some embodiments, the compressionspring 424 may be actuated via shortening or compression from itsresting length to provide a predictable reactive force. In someembodiments, the compression spring 424 may be defined by a spring ofthe springs 402 being in compression when the belt tensioner 144 isinstalled and engaged with the drive belt 108, as described herein. Itshould be noted, however, that in some embodiments, the springs 402 mayinclude one or more springs that are configured to function as both acompression spring and/or a tension spring, as discussed above.

As illustrated in the current embodiment, the belt tensioner 114 may bepositioned relative to the drive belt 108, such that the belt tensioner114 is configured to contact the drive belt 108, via the idler pulley404, adjacent to the first side 430 of the idler arm 406. In thismanner, as the drive belt 108 contacts the idler pulley 404 and impartsa reactive load against the idler pulley 404, the tension spring 422 mayreactively elongate or be placed in tension, and the compression spring424 may reactively compress or be placed in compression.

The belt tensioner 114 is configured to automatically adjust a tensionin the drive belt 108 via the springs 402. For example, as opposed torigid belt tensioners, the belt tensioner 114 may be configured todynamically or actively reposition the idler pulley 404 in response to atension or lack thereof in the drive belt 108. To illustrate, while theidler pulley 404 is in contact with the drive belt 108, the drive belt108 may impart a force or reactive load on the idler pulley 404, whichcauses rotation of the idler arm 406 about the pivot point 410. Therotation of the idler arm 406 causes the springs 402 to actuate andprovide a reactive force on the idler pulley 404 through the idler arm406. For example, when a tension in the drive belt 108 is reduced duringoperation of the blower assembly 102, the reactive force provided by thesprings 402 may cause the idler pulley 404 and the idler pulley assembly400 to impart a force on the drive belt 108 and to further increasetension in the drive belt 108. When a tension of the drive belt 108increases during operation of the blower assembly 102, the reactiveforce provided by the springs 402 may decrease and cause the idlerpulley 404 and the idler pulley assembly 400 to decrease a force appliedon the drive belt 108. Accordingly, the belt tensioner 114 may bepositioned such that the idler pulley 404 contacts the drive belt 108and the springs 402 are linearly actuated, such as through compressionof the compression spring 424 and extension of the tension spring 422based on an active tension in the drive belt 108. As used herein, aposition of the drive belt 108 may refer to a path along which the drivebelt 108 travels, such as between the motor pulley 110 and the blowerpulley 112, during operation of the blower assembly 102. Accordingly,deflection of the drive belt 108 may refer to displacement of the drivebelt 108 from the path at a point along the path.

In some embodiments, as the drive belt 108 loosens over time, the forceapplied to the springs 402 by the drive belt 108 may correspondinglydecrease, which may cause the tension spring 422 to compress and thecompression spring to elongate 424. This actuation of the springs 402may cause increased deflection of the drive belt 108 to substantiallymaintain a desired tension in the drive belt 108. In other words, thesprings 402 may dynamically respond, such as via linear actuation, to aloss of tension in the drive belt 108 by increasing the distance towhich the drive belt 108 is deflected, thereby substantiallyautomatically maintaining a desired tension in the drive belt 108. Insome embodiments, the actuation of the springs 402 as described abovemay be a result of fluctuations, or small deflections, in the positionof the drive belt 108 during normal operation. As the drive belt 108fluctuates, the springs 402 may actuate as described above to bias theidler pulley 404 toward and in contact with the drive belt 108 tosubstantially maintain a tension in the drive belt 108. That is, thesprings 402 may cause the idler pulley 404 to reactively move inconjunction with the fluctuations of the drive belt 108 to maintainsteady engagement between the idler pulley 404 and the drive belt 108.

As shown in the currently illustrated embodiment, the belt tensioner 114is positioned such that the idler pulley 404 is disposed external to theinterior region 270 defined by the drive belt 108. Thus, with the idlerpulley 404 positioned external to or outside of the interior region 270,the idler pulley 404 is configured to contact the exterior edge orsurface 272 of the drive belt 108 to adjust tension in the drive belt108. However, in some embodiments, the belt tensioner 114 may bepositioned such that the idler pulley 404 is disposed within theinterior region 270. In such embodiments, the idler pulley 404 isconfigured to contact the interior edge or surface 274 of the drive belt108 to adjust tension in the drive belt 108.

In the currently illustrated embodiment, the belt tensioner 114 iscoupled directly to the blower housing 116 via the mounting bracket 408.In some embodiments, as discussed in further detail below, the mountingbracket 408 may be coupled to a mounting plate and/or blower structure,which in turn may be coupled to the blower housing 116 or otherstructure of the blower assembly 102. Further, the belt tensioner 114may include a tensioner housing 440 disposed about the mounting bracket408 and about a portion of the idler arm 406. Indeed, the idler arm 406may be disposed substantially within the tensioner housing 440 with thedistal end 407 extending from the confines of the tensioner housing 440.That is, the idler pulley 404 mounted to the distal end 407 may remainexposed to contact the drive belt 108. In other words, the tensionerhousing 440 may substantially encompass the belt tensioner 114, exceptfor the distal end 407 of the idler arm 406 and the idler pulley 404. Insome embodiments, the tensioner housing 440 may include a portiondisposed between the mounting bracket 408 and the blower housing 116.For example, one or more fasteners configured to couple the mountingbracket 408 to the blower housing 116 may extend sequentially throughthe mounting bracket 408, through the tensioner housing 440, and throughthe blower housing 116 to mount the belt tensioner 114 to the blowerhousing 116. In this way, the tensioner housing 440 may substantiallyencapsulate the belt tensioner 114 and is configured to block or inhibitcontaminants, such as debris or fluids, from interacting with componentsof the belt tensioner 114. Specifically, tensioner housing 440 mayprotect the springs 402 and the pivot fastener 420 from the contaminantsto increase the longevity of the belt tensioner 114.

FIG. 21 is a perspective view of an embodiment of the belt tensioner114. As shown, the idler arm 406 is coupled to the mounting bracket 408via the springs 402 and the pivot fastener 420. The tension spring 422may be coupled to the first arm extension 432 of the mounting bracket408, and the compression spring 424 may be coupled to the second armextension 436 of the mounting bracket 408. The pivot fastener 420 may becoupled to the idler arm 406 and to a third arm extension 450 of themounting bracket 408. Indeed, as shown, the mounting bracket 408 mayinclude a base or backing portion 452, the first arm extension 432, thesecond arm extension 436, and the third arm extension 450. The backingportion 452 may include be a substantially flat piece of rigid material,such as metal, configured to receive one or more fasteners through oneor more mounting holes 451 to couple the mounting bracket 408 to theblower housing 102. Further, as shown, in some embodiments, the backingportion 450 may include three distinct arms 460, from which each of thefirst, second, and third arm extensions 432, 436, 450 may respectivelyextend. In some embodiments, the backing portion 452 may includeconnecting portions 462 disposed between edges of the arms 460, asshown, for additional support.

Each of the first, second, and third arm extensions 432, 436, 450 mayinclude an extension portion 470 and a mounting portion 472. Theextension portions 470 may extend substantially perpendicularly, or atany other suitable angle, from respective edges of the backing portion452 and the respective arms 460. The mounting portions 472 may furtherextend substantially perpendicularly, or at any other suitable angle,from respective ends of the extension portions 454. As a result, themounting portions 472 may extend substantially parallel to the backingportion 452 and may be spaced apart from the backing portion 452 via theextension portions 470. However, it should be appreciated that theextension portions 470 and mounting portions 472 may have otherorientations in other embodiments.

As shown, the idler arm 406 may be coupled to the mounting portion 472of each of the first, second, and third arm extensions 432, 436, 450.Particularly, the idler arm 406 is coupled to the third arm extension450 via the pivot fastener 420, which extends through the idler arm 406and through the mounting portion 472 of the third arm extension 450. Theidler arm 406 is coupled to the first arm extension 432 via the tensionspring 422, which extends between and is coupled to the first side 430of the idler arm 406 and the mounting portion 472 of the first armextension 432. Specifically, as shown, the first side 430 may include aseries of attachment points 480, such as holes, pins, hooks, tensionadjustment features, and/or other connection points, to which thetension spring 422 may be coupled. The mounting portion 472 of the firstarm extension 432 may include a mounting attachment point 482, such as ahole, hook, or other mounting feature, to which the tension spring 422may also be coupled. For example, in the currently illustratedembodiment, the tension spring 422 includes two hooks 484 disposed atrespective ends of the tension spring 422. One of the hooks 484 mayextend through the one of attachment points 480, and the other of thehooks 484 may extend through the mounting attachment point 482 to couplethe idler arm 406 to the first arm extension 432. As shown, theattachment points 480 may provide discrete attachment points for thetension spring 422. In some embodiments, the attachment points 480 mayinclude continuous attachment points, such as a sliding mechanism orelongated slot, for the tension spring 422 to couple to the idler arm406. In some embodiments, the tension spring 422 may include anysuitable coupling elements, such as fasteners, disposed at the ends ofthe tension spring 422 that are configured to couple to any suitablecorresponding coupling elements, such as springs 402, of the idler arm406 and the first arm extension 432. As will be appreciated, the tensionspring 422 may be coupled to any of the attachment points 480 to adjusttension in the tension spring 422. For example, the tension spring 422is configured to separately couple to a first attachment point 480 and asecond attachment point 480 to adjust a force applied to the idler arm406 by the tension spring 422.

The idler arm 406 is further coupled to the second arm extension 436 viathe compression spring 424, which extends between and is coupled to thesecond side 434 of the idler arm 406 and the mounting portion 472 of thesecond arm extension 436. Particularly, as shown, a first edge 483 ofthe mounting portion 472 of the second arm extension 436 and a secondedge 485 of the second side 434 of the idler arm 406 may each include acoupling element 486 to which the compression spring 424 may be coupled.In the currently illustrated embodiment, the coupling element 486includes a substantially cylindrical extension configured to extendthrough or into an internal diameter of the compression spring 424. Inother words, ends of the compression spring 424 may extend about outersurfaces of the coupling elements 486. In some embodiments, thecompression spring 424 may be integrally coupled or fixed to thecoupling elements 486, such as via welding or fasteners. Additionally oralternatively, the compression spring 424 may be supportively coupled tothe coupling elements 486, such that the compression spring 424 mayuncouple from the coupling elements 486 if a distance between thecoupling elements 436 increases beyond a resting length of thecompression spring 424. The connecting elements 486 may be integrallypart of, or coupled to, the first edge 483 of the second arm extension436 and the second edge 485 of the second side 434 of the idler arm 406.As shown, the first edge 483 and the second edge 485 may both be anglededges that are angled to face each other. Accordingly, the compressionspring 424 may compress substantially linearly as the second edge 485moves toward the first edge 483 during operation of the belt tensioner114, as described herein.

The tension spring 422 may be coupled to the idler arm 406 and the firstarm extension 432 at a first angle 492 relative to a longitudinal axis496 of the idler arm 406. The longitudinal axis 496 of the idler arm 406may extend through the pivot point 410, as shown. In some embodiments,the longitudinal axis 496 may define a boundary or midpoint between thefirst side 430 and the second side 434 of the idler arm 406. In someembodiments, the first side 430 and the second side 434 of the idler arm406, as defined by the longitudinal axis 496, may further refer torespective first and second sides of the idler pulley 404 relative tothe longitudinal axis 496. The compression spring 424 may be coupled tothe idler arm 406 and to the second arm extension 436 at a second angle497 relative to the longitudinal axis 496. In some embodiments, thefirst angle 492 and/or the second angle 497 may be determined based on adesired force to be applied to the drive belt 108 via the idler pulley404. Generally, respective torques applied to the idler arm 406 from thetension spring 422 and the compression spring 424 may determine theamount of force applied to the drive belt 108 via the idler pulley 404.

Keeping this in mind, the first angle 492 may be adjusted by changingthe attachment point 480 on the idler arm 406 to which the tensionspring 422 is coupled. In some embodiments, assuming a constant tensileforce in the tension spring 422, as the first angle 492 increases, thedirection of force of applied to the idler arm 406 may move towardsbeing substantially perpendicular relative to the longitudinal axis 494.Accordingly, in such embodiments, the torque applied to the idler arm406 may increase as the first angle 492 increases. However, in someembodiments, the tension in the tension spring 422 may increase, such asdue to elongation of the tension spring 422, as the first angle 492decreases, which may cause an increase to the torque applied to theidler arm 406. As such, a user may exchange the tension spring 422 toadjust the k constant or resting length of the tension spring 422 and/ormay adjust the first angle 492 in order to adjust a torque applied tothe idler arm 406 by the tension spring 422.

Similarly, in some embodiments, the second angle 497 may be chosen, suchas during manufacturing of the first and second edges 483, 485, toselect the torque applied to the idler arm 406 by the compression spring424. Indeed, similar to the first angle 492, assuming a constantcompressive force in the compression spring 424, as the second angle 497increases, the direction of force of applied to the idler arm 406 maymove towards being substantially perpendicular relative to thelongitudinal axis 494. Accordingly, in such embodiments, the torqueapplied to the idler arm 406 may increase as the second angle 492increases. As such, a user may exchange the compression spring 424 toadjust the k constant or resting length of the compression spring 424and/or a manufacturer may adjust the second angle 497 in order to adjusta torque applied to the idler arm 406 by the tension spring 422.

FIG. 22 is an exploded perspective view of an embodiment of the belttensioner 114. As shown, the belt tensioner 114 includes the idler arm406, the idler pulley assembly 400, the pivot fastener 420, the mountingbracket 408, and additional elements, as described herein. The idler arm406 includes a spring mounting portion 500, an idler pulley mountingportion 502, and an offset portion 504. The offset portion 504 extendsbetween the spring mounting portion 500 and the idler pulley mountingportion 502. The spring mounting portion 500 may be coupled to thesprings 402, as discussed above. The spring mounting portion 500 mayalso include a pivot aperture 506 disposed about the pivot point 410 andconfigured to receive the pivot fastener 420. The idler pulley mountingportion 502 may be disposed substantially parallel to the springmounting portion 500 and includes the distal end 407. The distal end 407includes an idler aperture 510 configured to receive the idler pulleyassembly 400, as discussed in further detail below. The offset portion504 may be disposed substantially perpendicularly, or at any suitableangle, to the spring mounting portion 500 and to the idler pulleymounting portion 502. The idler pulley mounting portion 502 is offsetfrom the spring mounting portion 500 by the offset portion 504 in orderfor the drive belt 108 to directly contact the idler pulley 404 and notcontact certain other portions of the belt tensioner 114 duringoperation. Indeed, as shown, the idler pulley mounting portion 502 maybe substantially disposed in a first plane, and the spring mountingportion 500 may be substantially disposed in a second plane. The firstplane and the second plane may be disposed substantially parallel toeach other and may be spaced part by the offset portion 504.

The idler pulley assembly 400 may include a shaft 512, a washer or ring514, the idler pulley 404, a bushing 516, a washer or ring 518, and anut 520. As shown, the shaft 512 may include a first side 522 and asecond side 524 defined by an annular ridge 526 disposed therebetween.The first side 522 of the shaft 512 may extend through the idleraperture 510. The first side 522 may couple to a nut or other fastenerto couple the shaft 512 to the idler arm 406. The second side 524 of theshaft 512 may extend sequentially through the ring 514, the idler pulley404, the bushing 516, the washer 518, and the nut 520, as shown. Thering 514 and the bushing 516 are configured to reduce frictionexperienced during rotation of the idler pulley 404. Indeed, the bushing516 may be disposed radially between the idler pulley 404 and the shaft512, relative to a longitudinal or rotational axis of the shaft 512, toreduce friction of the idler pulley 404 on the shaft 512. The nut 520 isconfigured to fasten the idler pulley 404 to the shaft 512, and thewasher 518 is configured to improve the fastening function of the nut520. However, it should be understood that the idler pulley assembly 400may include any suitable types and arrangements of components to fastenthe idler pulley 404 to the distal end 407 of the idler arm 406 and toreduce friction of the idler pulley 404 on the shaft 512 during rotationof the idler pulley 404. Further, as discussed herein, the idler pulley404 may be formed of a nylon material configured to promote or enableself-lubrication of the idler pulley 404. That is, the nylon material ofthe idler pulley 404 may transfer microscopic amounts of material to thebushing 516, or other surface against which the idler pulley 404 mayrotate, to create a film that lubricates an interface between thebushing 516 and the idler pulley 404.

The pivot fastener 420 may include a bolt 530, a first washer 532, abushing 534, a second washer 536, a gasket 538, and a nut 540. As shown,the bolt 530 may extend sequentially through the first washer 532, thebushing 534, the pivot aperture 506, a mounting aperture 508 disposedthrough the mounting portion 472 of the third arm extension 450 of themounting bracket 408, the second washer 536, the gasket 538, and the nut540. The bushing 534 may be disposed radially between the idler arm 406and the bolt 530, relative to longitudinal or rotational axis of thebolt 530, to reduce friction between the idler arm 406 and the bolt 530during rotation of the idler arm 406. The first and second washers 532,536 are configured to improve coupling between elements of the pivotfastener 420, such as by increasing distributions of fastening forces ofthe bolt 530 and of the nut 540. The gasket 538 is configured to enablesealing and/or reduce abrasion or corrosion between elements of thepivot fastener 420. However, it should be understood that the pivotfastener 420 may include any suitable types and arrangements ofcomponents to fasten the idler arm 406 to the third arm extension 450 ofthe mounting bracket 408 and to reduce friction during rotation of theidler arm 406.

As discussed above, the mounting bracket 408 is configured to be coupleddirectly to the blower housing 116. Accordingly, the mounting bracket408 may include the mounting holes 451 configured to receive mountingfasteners 552, such as screws, bolts, rivets, or other fasteners. Themounting fasteners 552 may extend through the backing portion 452 of themounting bracket 408 and engage with an external surface, such as theblower housing 116 or other structure of the blower assembly 102, tomount the belt tensioner 114 to the external surface.

FIGS. 23 and 24 are side views of the belt tensioner 114 coupled to ablower structure 560, such as a mounting plate, in various arrangementsrelative to the drive belt 108. The blower structure 560 may be a partof the blower housing 116, part of the blower assembly 102, and/or apart of a separate panel that is coupled to the blower housing 116. Asshown, the belt tensioner 114 may be positioned relative to the drivebelt 108 such that the belt tensioner 114 contacts the drive belt 108adjacent to the first side 430 of the idler arm 406. In other words, thebelt tensioner 114 may contact the drive belt 108 such that, in responseto the idler pulley 404 contacting the drive belt 108, the tensionspring 422 may elongate and the compression spring 424 may compress.Particularly, it should be understood that the belt tensioner 114 may beutilized with any orientation of the drive belt 108 as long as the belttensioner 114 is configured to contact the drive belt 108 adjacent tothe first side 430 to enable actuation of the springs 402, as describedabove.

Specifically, FIG. 23 is a side view of the belt tensioner 114 engagedwith the drive belt 108, where the belt tensioner 114 is configured tobe linearly adjusted relative to the blower structure 560 and relativeto the drive belt 108. To this end, the blower structure 560 may includeone or more linear adjustment slots 562. The linear adjustment slots 562may be elongated, substantially linear slots disposed through the blowerstructure 560 that are configured to receive the mounting fasteners 522.Particularly, as shown, the mounting fasteners 522 may extend throughthe mounting bracket 408 and engage with the linear adjustment slots562. The mounting fasteners 522 may be torqued in a first direction, ortightened, to fix the mounting bracket 408 to the blower structure 560at a desired linear position along the linear adjustment slots 562. Themounting fasteners 522 may be torqued in a second direction, orloosened, to loosen the mounting fasteners 522 and allow linearpositional adjustment of the mounting fasteners 522 and the mountingbracket 408 along the linear adjustment slots 562. In this manner, aposition of the belt tensioner 114 may be linearly adjustable relativeto the drive belt 108, and a force of belt tensioner 114 applied to thedrive belt 108 may be correspondingly adjusted. Indeed, as the belttensioner 114 is adjusted linearly towards the drive belt 108, the forceapplied by the idler pulley 404 to the drive belt 108 may increase.Correspondingly, as the belt tensioner 114 is adjusted linearly awayfrom the drive belt 108, the force applied by the idler pulley 404 tothe drive belt 108 may decrease.

Further, FIG. 24 is a side view of the belt tensioner 114 engaged withthe drive belt 108 and configured to be rotationally adjusted relativeto the blower structure 560 and relative to the drive belt 108. To thisend, the blower structure 560 may include one or more arcuate adjustmentslots 564. The arcuate adjustment slots 564 may be elongated,substantially arcuate or circumferential slots formed through the blowerstructure 560 that are configured to receive the mounting fasteners 522.Particularly, as shown, the mounting fasteners 522 may extend throughthe mounting bracket 408 and engage with the arcuate adjustment slots564. The mounting fasteners 522 may be torqued in a first direction, ortightened, to fix the mounting bracket 408 to the blower structure 560at a desired rotational position. The mounting fasteners 522 may betorqued in a second direction, or loosened, to loosen the mountingfasteners 522 and allow rotational, positional adjustment of themounting fasteners 522 and the mounting bracket 408 along the arcuateadjustment slots 564. In this manner, a position of the belt tensioner114 may be rotationally adjustable relative to the drive belt 108. Assuch, the force applied by the belt tensioner 114 to the drive belt 108may be adjusted. Indeed, as the belt tensioner 114 is adjustedrotationally towards the drive belt 108, such as in a counter-clockwisedirection 566, the force applied by the idler pulley 404 to the drivebelt 108 may increase. Correspondingly, as the belt tensioner 114 isadjusted rotationally away from the drive belt 108, such as in aclockwise direction 568, the force applied by the idler pulley 404 tothe drive belt 108 may decrease.

In some embodiments, the belt tensioner 114 may be implemented as aretrofit application to a previously-existing, such as apreviously-installed or previously-manufactured, blower or blowerassembly 102. Additionally or alternatively, the belt tensioner 114 maybe manufactured and installed with the blower assembly 102 by anoriginal equipment manufacturer (OEM) when the blower assembly 102 isoriginally manufactured. Further, it is to be understood that the belttensioner 114, as discussed herein, may be applied to any applicationthat may utilize a drive belt to drive operation of one or morecomponents, such as automotive applications, power productionapplications, HVAC applications, and so forth. Moreover, it should alsobe understood that features of any of the embodiments discussed hereinmay be combined with any other embodiments or features discussed herein.

Accordingly, the present disclosure is directed to a belt tensioner fora blower assembly that is configured to maintain a tension in a drivebelt to avoid slippage of the drive belt during normal loadingconditions and to enable efficient and convenient adjustment of thetension in the drive belt. The belt tensioner may be rigidly mounted toa blower housing of a blower assembly. Particularly, the belt tensionermay include a mounting bracket that is rigidly coupled to the blowerhousing. In one embodiment, the belt tensioner further includes anadjustment assembly configured to enable rotation of an idler arm and anidler pulley about a fulcrum to adjust a tension in the drive belt. Theidler arm may be L-shaped, such that the adjustment assembly isconfigured to cause a first portion of the idler arm to increase a forceon the drive belt by rotating a second portion, which extends at anangle from the first portion, about a fulcrum of the L-shaped idler arm.

In some embodiments, the belt tensioner may include a lock plate and aguide rail coupled directly to the blower housing. The belt tensionermay further include an idler mounting plate configured to mount an idlerpulley thereto and configured to translate within the guide rail as aresult of torqueing of a bolt extending through the lock plate and theidler mounting plate.

In some embodiments, the belt tensioner may include a mounting platecoupled directly to the blower housing, an idler arm coupled to themounting plate and configured to couple to an idler pulley, and a set oflinear springs coupled to the idler arm and to the mounting plate. Theset of linear springs are configured to actuate in response to areactive load applied to the idler pulley by the drive belt duringengagement between the idler pulley and the drive belt. In this manner,the pair of springs may automatically adjust a tension in the drive beltas the drive belt loosens over time or fluctuates during normaloperation.

Accordingly, the belt tensioner is configured to adjust a tension in adrive belt through simple adjustments and without positional adjustmentof shafts or pulleys that are drivingly linked by the drive belt.

While only certain features and embodiments of the present disclosurehave been illustrated and described, many modifications and changes mayoccur to those skilled in the art, such as variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials,orientations, and so forth, without materially departing from the novelteachings and advantages of the subject matter recited in the claims.The order or sequence of any process or method steps may be varied orre-sequenced according to alternative embodiments. It is, therefore, tobe understood that the appended claims are intended to cover all suchmodifications and changes as fall within the true spirit of thedisclosure. Furthermore, in an effort to provide a concise descriptionof the embodiments, all features of an actual implementation may nothave been described, such as those unrelated to the presentlycontemplated best mode of carrying out the disclosure, or thoseunrelated to enabling the claimed features. It should be appreciatedthat in the development of any such actual implementation, as in anyengineering or design project, numerous implementation specificdecisions may be made. Such a development effort might be complex andtime consuming, but would nevertheless be a routine undertaking ofdesign, fabrication, and manufacture for those of ordinary skill havingthe benefit of this disclosure, without undue experimentation.

1. A belt tensioner for a blower assembly, comprising: a mountingbracket configured to couple directly to the blower assembly; an idlerarm configured to couple to the mounting bracket at a connection pointand in an angular position relative to a base of the blower assembly,wherein the angular position is adjustable about the connection point;and an idler pulley coupled to the idler arm, wherein the idler pulleyis configured to engage with a drive belt of the blower assembly.
 2. Thebelt tensioner of claim 1, wherein the mounting bracket is configured tocouple directly to a blower housing of the blower assembly.
 3. The belttensioner of claim 1, wherein the idler arm comprises an idler pulleymount and an adjustment plate disposed crosswise to the idler pulleymount, wherein the idler pulley is coupled to the idler pulley mount,and wherein the adjustment plate is configured to engage with an angularadjuster of the belt tensioner.
 4. The belt tensioner of claim 3,comprising the angular adjuster, wherein the angular adjuster includes abolt extending through the adjustment plate and through the mountingbracket, and wherein rotation of the bolt adjusts the angular position.5. The belt tensioner of claim 4, wherein the adjustment plate has anelongated slot, and wherein the bolt extends through the elongated slot.6. The belt tensioner of claim 4, comprising a spring disposed about thebolt between the adjustment plate and the mounting bracket to bias theadjustment plate and the mounting bracket away from one another.
 7. Thebelt tensioner of claim 4, wherein the angular adjuster includes; acurved cup coupled to the mounting bracket, and a curved washer disposedabout and along the bolt, wherein the curved washer is configured toslide within the curved cup to enable angular movement of the boltrelative to the mounting bracket.
 8. The belt tensioner of claim 3,wherein the idler pulley mount has an L-shaped configuration, andwherein a fastener extends through a fulcrum of the L-shapedconfiguration to couple the idler arm to the mounting bracket.
 9. Thebelt tensioner of claim 8, wherein the L-shaped configuration of theidler pulley mount has a first portion coupled to the idler pulley and asecond portion extending crosswise to the first portion relative thefulcrum.
 10. The belt tensioner of claim 3, wherein the idler pulleymount and the adjustment plate are integrally formed as one piece. 11.The belt tensioner of claim 3, comprising the angular adjuster, whereinthe angular adjuster has a bolt extending through the mounting bracketand configured to abut a surface of the adjustment plate.
 12. The belttensioner of claim 1, wherein the idler arm includes an arcuate slot anda fastener extending through the arcuate slot, and wherein the fasteneris configured to travel within the arcuate slot during adjustment of theangular position of the idler arm.
 13. A heating, ventilation, and/orair conditioning (HVAC) system, comprising: a blower assembly includinga blower, a blower housing configured to house the blower, a motorconfigured to provide rotational power, and a drive belt configured totransfer the rotational power from the motor to the blower; and a belttensioner including an L-shaped support having a first arm coupled to anidler pulley and having a second arm, wherein the first arm and thesecond arm are coupled to one another at a bend, wherein the L-shapedsupport is rotatably coupled to the blower housing via a mountingbracket, wherein the idler pulley is configured to contact the drivebelt to facilitate tensioning of the drive belt.
 14. The HVAC system ofclaim 13, wherein the idler pulley is coupled to a distal end of thefirst arm.
 15. The HVAC system of claim 13, wherein the L-shaped supportis configured to rotate about a fulcrum, disposed at the bend betweenthe first arm and the second arm, to facilitate the tensioning of thedrive belt.
 16. The HVAC system of claim 13, wherein the second armincludes an arcuate slot therethrough, wherein the belt tensionerincludes a bolt extending through the arcuate slot, and wherein thearcuate slot is configured to slide along the bolt during rotation ofthe L-shaped support.
 17. The HVAC system of claim 13, wherein the belttensioner includes an adjustment plate integrally formed with, anddisposed crosswise to, the L-shaped support, and wherein the belttensioner has a bolt extending through the mounting bracket andconfigured to apply a force to the adjustment plate to adjust a positionof the L-shaped support to adjust the tensioning of the drive belt. 18.The HVAC system of claim 17, wherein the adjustment plate includes anelongated slot therethrough, and the bolt extends through the elongatedslot.
 19. The HVAC system of claim 17, wherein the belt tensionerincludes a hex rivet nut extending through and fixed to the mountingbracket, and wherein the bolt extends through the hex rivet nut.
 20. Ablower assembly for a heating, ventilation, and/or air conditioning(HVAC) system comprising: a blower fan; a blower housing containing theblower fan; a drive belt coupled to the blower fan and configured todrive rotation of the blower fan; and a belt tensioner including anL-shaped bracket that is coupled to the blower housing via a mountingbracket, wherein the L-shaped bracket is rotatably coupled to themounting bracket at a bend of the L-shaped bracket.
 21. The blowerassembly of claim 20, comprising an adjustment plate integrally formedwith the L-shaped bracket and disposed crosswise to the L-shapedbracket.
 22. The blower assembly of claim 21, comprising an adjustmentassembly having a threaded bolt extending through the mounting bracket,wherein the threaded bolt is adjustable to apply a force to theadjustment plate to rotate the L-shaped bracket.
 23. The blower assemblyof claim 22, wherein the threaded bolt is configured to be linearlytranslated relative to the adjustment plate to cause the L-shapedbracket to rotate about the bend.
 24. The blower assembly of claim 20,wherein the L-shaped bracket has a first portion coupled to an idlerpulley of the belt tensioner and a second portion having an arcuate slottherethrough, wherein the arcuate slot is configured to slide along abolt of the belt tensioner during rotation of the L-shaped bracket.